Methods for compression molding foam articles

ABSTRACT

Compression molded foam articles are provided having a closed cell foam structure comprising a plurality of cells having an anisotropic cell shape. The disclosed compression molded foam articles can be used as components or parts of a variety of articles, including articles of footwear and athletic equipment. Methods are disclosed for making the disclosed compression molded foam articles from a foamed preform having an elastomeric closed cell foam with substantially isotropic cell shape. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of, and claims priority to,co-pending U.S. application Ser. No. 16/458,606, filed on Jul. 1, 2019,which is a continuation of U.S. application Ser. No. 16/396,674, filedon Apr. 27, 2019 and now issued as U.S. Pat. No. 10,383,396, whichclaims the benefit of U.S. Provisional Application No. 62/664,052, filedon Apr. 27, 2018, each of which is incorporated herein by reference inits entirety.

TECHNICAL FIELD

The present disclosure generally relates to molded polymeric foams, andin particular to molded polymeric foams for the footwear and relatedindustries and uses thereof.

BACKGROUND

The design of athletic equipment and apparel as well as footwearinvolves a variety of factors from the aesthetic aspects, to the comfortand feel, to the performance and durability. While design and fashionmay be rapidly changing, the demand for increasing performance in themarket is unchanging. To balance these demands, designers employ avariety of foam materials and designs for the various components thatmake up athletic equipment and apparel as well as footwear, includingcushioning elements.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present disclosure will be readily appreciatedupon review of the detailed description, described below, when taken inconjunction with the accompanying drawings.

FIGS. 1A-1B are views of exemplary aspects of an article of footwearaccording to an aspect of the present disclosure. FIG. 1A is anisometric view of an exemplary aspect of an article of footwearaccording to aspects of the present disclosure. FIG. 1B is an explodedview of the article of footwear in FIG. 1A.

FIG. 2 is a bottom plan view of the article of footwear of FIG. 1A.

FIGS. 3A-3I show top plan views of a representative compression mold fora midsole showing a mold cavity therein without a foamed preform, with afoamed preform before compression molding, and a compression molded foamarticle after compression molding as described in further detail hereinbelow. In some instances, reference lines 101 and 102 are showncorresponding to a cross-sectional plan view at the indicated positionfor parallel to the x-axis or y-axis, respectively. The respectivecross-sectional views are shown in FIGS. 4A-4I (along reference line 101for a cross-section plan view in the x-axis) and FIGS. 4J-4R (alongreference line 102 for a cross-section plan view in the y-axis).

FIGS. 4A-4I and 4P-4U show cross-sectional plan views at a positionmarked by reference line 101 shown in FIGS. 3A-3I, respectively, andFIGS. 4J-40 and 4V-4X show cross-sectional plan views at a positionmarked by reference line 102 shown in FIGS. 3J-3R, respectively.

FIGS. 5A-5D are top plan views of a representative compression mold fora midsole with preform arranged therein prior to compression molding.FIG. 5A shows a representative mold gap of the present disclosure atwidth reference line 101 a. FIG. 5B shows a representative mold gap ofthe present disclosure at width reference line 101 b. FIG. 5C shows apreform in a mold cavity in which a varying gap is located between thecontoured perimeter edge generally along the y-axis in the toe region ofthe preform and the contoured boundary of the mold cavity in the toeregion and highlights a representative mold gap of the presentdisclosure at width reference line 101 a. FIG. 5D shows a preform in amold cavity in which a varying gap is located between the contouredperimeter edge generally along the y-axis in the toe region of thepreform and the contoured boundary of the mold cavity in the toe regionand highlights a representative mold gap of the present disclosure atwidth reference line 101 b.

FIGS. 6A-6C are top plan views of a representative compression mold foran article with a rectangular shape, e.g., a sample plaque, in the topplan view with a regular gap width parallel to the y-axis with a foamedpreform arranged therein prior to and after compression molding. FIG. 6Ashows the representative compression mold for an article on the left ofthe figure and a representative preform that can be used with thecompression mold shown. FIG. 6B shows the representative compressionmold for an article of FIG. 6A with the representative foamed preformplaced therein and prior to compression molding. As shown in FIG. 6B,there is a regular and even gap between each of the left and right outeredges of the preform and the inner face of the compression mold. FIG. 6Cshows the representative compression mold for an article of FIG. 6A withthe molded article after compression molding. As shown in FIG. 6C, therecompression molding of the preform has resulted in the loss of the gapbetween each of the left and right outer edges of the preform and theinner face of the compression mold, and provides an anisotropic cellshape in the compression molded article.

FIG. 7 shows representative cyclic loading data for a representativefoam midsole (heel loading) having anisotropic closed cell foamstructure.

FIG. 8 shows representative cyclic loading data for a representativemolded plaque specimen having anisotropic closed cell foam structure.

FIG. 9A shows a representative side view of a midsole such as that usedto obtain the data in FIG. 7 . FIG. 9B shows a photographic imageshowing the representative geometry and testing of a portion of thetesting apparatus that contacts a midsole. The testing method andapparatus are as further described herein below and were used to obtainthe data in FIG. 7 .

FIGS. 10A-10D show representative high contrast optical micrographs ofrepresentative foam plaque specimen cross-sections made using thedisclosed methods. The scale bar shown in the lower right of each imageis 500 micrometers.

DETAILED DESCRIPTION

New designs and materials for the footwear industry are needed. Inparticular, there remains a need for polymeric foams having improvedphysical properties, for example that can be used in the footwearindustry to provide improved cushioning and energy return when used in amidsole or other component for an article of footwear.

Conventional compression molding processes are commonly used to formcompression molded foam articles such as cushioning elements for use infootwear, e.g. a midsole. These processes are used to convert foam“preforms” to compression molded foam articles having properties whichare desirable for footwear components, such as improved surface hardnessand compression set. In conventional compression molding processes, afoam preform is enclosed in a mold cavity under compression, therebyincreasing the density of the foam material. The foam material in theclosed mold is then heated order to soften the foam, creating a skin onthe foam which takes on the conformation of the molding surface. Inaddition to reducing the size of the preform (usually the height isreduced by at least 10 percent), increasing the density of the foammaterial, and altering the conformation and thickness of the externalskin, the process typically alters the hardness, split tear, and tensilestrength of the compression molded foam article as compared to thepreform.

Typically, the molds used in conventional compression molding processesare multi-part molds (i.e., molds having molding surfaces spread acrosstwo or more parts), where the multiple parts of the mold, when closed,combine to form a mold cavity constrained along the x, y and z axes.Typically for footwear, the last part of the mold to be put in place isthe part which constrains the mold along the z axis. When using a foamedpreform having a pre-defined three-dimensional shape, the dimensions ofthe preform along the x and y axes are very close to if not the same asor slightly greater than the dimensions of the mold cavity along the xand y axes, as the preform is configured to fit easily within the moldcavity with little or no gap existing along the x and y axes. But alongthe z axis (corresponding to the height dimension), the dimension of thepreform is greater than the dimension of the mold cavity, e.g., theheight of the preform exceeds the height of the mold. It is understoodthat the height of the mold corresponds to the maximum height (i.e.,dimension along the z-axis) when the mold is closed. The mold typicallycomprises a lower mold part and an upper mold part that sits atop thepreform. The upper mold part is in contact with the preform, and aheated platen applies pressure to the upper mold part during compressionmolding, compressing the preform into the mold cavity. Typically thepreform is about 110 percent to about 180 percent greater along thez-axis compared to the depth of the mold. Thus, the total volume of thepreform is greater than the total volume of the mold cavity.

In conventional compression molding processes, the foam preformtypically has a substantially isotropic cell structure or an isotropiccell structure. That is, the majority of the cells in the cell structuretypically have a similar size and dimension in each of the three axes(x-, y-, and z-axis) that described the three physical dimension of thecompression molded foam article. One consequence of the substantiallyisotropic or isotropic cell structure, as realized in conventionallymolded foam articles, is that a physical property associated with themolded foam article will have isotropic character. For example, energyreturn is intimately associated with various aspects of the cellstructure. As such, energy return will have an isotropic response forenergy return determined for each of the three axes (x-, y-, and z-axis)of the molded foam article. That is, the energy return determined alongeach of three axes have similar energy return values. Other physicalproperties, e.g., stiffness, can also show isotropic responses if thecompression molded foam article has a substantially isotropic orisotropic cell structure.

The present disclosure, pertains, in part, to molded foam articles thathave an anisotropic cell structure. The anisotropic cell structure inthe disclosed molded foam articles is associated with the compressionmolded foam article having at least one physical property that isanisotropic along at least one axis compared to one or both of the othertwo axes.

The present disclosure, further pertains, in part, to methods ofpreparing compression molded foam articles that surprisingly permitmanufacture of molded foam articles that have a greater level ofanisotropic cell structure as compared to the foam preform, bycompression molding foamed preforms having unique geometries relative tothe mold cavity used. The greater anisotropic cell structure in thedisclosed molded foam articles is associated with the molded foamarticle having at least one physical property that is anisotropic alongat least one axis compared to one or both of the other two axes. In aparticular aspect, the molded foam articles made using the disclosedmethods exhibit at least one physical property with greater anisotropiccharacter along the axis that is parallel to the direction in whichcompression is applied. Thus, if a z-axis for a disclosed molded foamarticle is defined as an axis parallel to the direction in whichcompression is applied, then a physical property, e.g., energy return orstiffness, is anisotropic along the z-axis compared to either of thex-axis, the y-axis, or both.

In a first aspect, the present disclosure is directed to molded foamarticles comprising: an elastomeric material having a closed cell foamstructure comprising a plurality of cells having an anisotropic cellshape; wherein the molded foam article comprises a first axis, a secondaxis and a third axis; wherein the first axis is perpendicular to thesecond axis and the third axis; wherein the second axis and the thirdaxis are each perpendicular to each other; and wherein the second andthe third axis define a plane parallel to a major surface of the moldedfoam article; wherein a physical property determined along the firstaxis is different from the physical property determined along the secondaxis, the third axis, or both the second and third axis.

In a second aspect, the present disclosure is directed to articlescomprising the molded foam articles of the first aspect. The articlescomprising the molded foam articles can be cushioning elements. Thearticles comprising the molded foam articles can be articles offootwear, articles of apparel, or articles of sporting equipment.

In a third aspect, the present disclosure is directed to methods ofmaking a compression molded foam article, the method comprising:arranging a preform in a compression mold; wherein the preform comprisesa polymeric foam material having a closed cell foam structure; whereinthe preform is associated with a preform x-axis, y-axis, and z-axis suchthat each axis is perpendicular to the other two; wherein the preformhas a preform longitudinal dimension parallel to the preform y-axis of apreform x-y plan; wherein the preform z-axis is parallel to thedirection of compression applied to the compression mold; wherein thepreform has a preform height that is a dimension parallel to the preformz-axis; wherein the preform has an initial preform height equal to thepreform height prior to compression molding; wherein the preform has apreform area comprising an area of a preform x-y plane; and wherein thepreform has an initial preform area that is the preform area prior tocompression molding; wherein the compression mold comprises a moldcavity; and wherein the mold cavity is associated with a mold cavityx-axis, y-axis, and z-axis such that each axis is perpendicular to theother two; wherein the mold cavity has a mold cavity longitudinaldimension parallel to the mold cavity y-axis of a mold cavity x-y plane;wherein the mold cavity z-axis is parallel to the direction ofcompression applied to the compression mold; wherein the mold cavity hasa mold cavity height that is a dimension parallel to the preform z-axiswhen the mold is closed; wherein the mold cavity has a mold cavity areacorresponding to an area of a mold cavity bottom; and wherein the moldcavity bottom is a mold cavity x-y plane opposite a mold cavity opening;wherein the initial preform area is less than about 95 percent the moldcavity area; wherein the arranging comprises aligning the preformx-axis, y-axis, and z-axis with the mold cavity x-axis, y-axis, andz-axis; and wherein the initial preform height is from about 1.1- toabout 5-fold greater than the mold cavity height; closing thecompression mold and compressing the preform into a closed mold cavity;applying heat, pressure, or a combination of both to the closed moldcavity for a duration of time to: (a) alter at least one preformdimension in the preform x-axis, y-axis, and z-axis; and (b) alter theclosed cell foam structure to a closed cell foam structure having agreater proportion of anisotropic cell shapes; opening the compressionmold after the least one preform dimension in the preform x-axis,y-axis, and z-axis and the closed cell foam structure are altered;removing the compression molded foam article from the compression mold;and forming the compression molded foam article; wherein the compressionmolded foam article retains dimensions of the closed mold cavity withinabout plus or minus 50 percent; and wherein the compression molded foamarticle has the closed cell foam structure having a greater proportionof closed cells with the anisotropic cell shapes as compared to thepreform, or having substantially the same proportion of closed cellswith the anisotropic cells shapes as compared to the preform, where anaverage aspect ratio of the proportion of the closed cells with theanisotropic cell shapes is greater as comparted to the preform, or boththe proportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the foam structure of the compression moldedfoam article as compared to the foam structure of the preform.

In a fourth aspect, the present disclosure is directed to methods ofmaking a compression molded foam article, the method comprising:arranging a preform in a compression mold; wherein the preform comprisesa polymeric material having a closed cell foam structure; wherein thepreform is associated with a preform x-axis, y-axis, and z-axis suchthat each axis is perpendicular to the other two; wherein the preformhas a preform longitudinal dimension parallel to the preform y-axis of apreform x-y plan; wherein the preform z-axis is parallel to thedirection of compression applied to the compression mold; wherein thepreform has a plurality of initial preform widths; wherein each initialpreform width of the plurality of initial preform widths is designatedas IPW_(i); wherein i is an integer having a value of 1 to 100; andwherein each IPW_(i) has a dimension parallel to the preform x-axis ofthe preform x-y plane at a position, Y_(i), along the preformlongitudinal dimension prior to compression molding; wherein the preformhas a preform height; wherein the preform height is a dimension parallelto the preform z-axis; and wherein the initial preform height is thepreform height prior to compression molding; wherein the compressionmold comprises a mold cavity associated with a mold cavity x-axis,y-axis, and z-axis such that each axis is perpendicular to the othertwo; wherein the mold cavity has a longitudinal dimension parallel tothe mold cavity y-axis of a mold cavity x-y plane; wherein the moldcavity z-axis is parallel to the direction of compression applied to thecompression mold; wherein the mold cavity has a plurality of mold cavitywidths; wherein each mold cavity width of the plurality of mold cavitywidths is designated as CW_(j); wherein j is an integer having a valueof 1 to 100; wherein each CW_(j) has a dimension parallel to the moldcavity x-axis of the mold cavity x-y plane of the preform at a position,P_(j), along the mold cavity longitudinal dimension; wherein the moldcavity has a mold cavity height that is a dimension parallel to thepreform z-axis when the mold is closed; wherein the arranging comprisesaligning the preform x-axis, y-axis, and z-axis with the mold cavityx-axis, y-axis, and z-axis; wherein each P_(i) is associated with acorresponding position of the preform longitudinal dimension when thepreform y-axis and the mold cavity y-axis are aligned; wherein theinitial preform height is from about 1.1- to about 5-fold greater thanthe mold cavity height; wherein the preform and the mold cavity areassociated with a plurality of mold gaps; wherein each mold gap of theplurality of mold gaps is designated as MG_(k); wherein k is an integerhaving a value of 1 to 100; wherein each MG_(k) is obtained from thefollowing equation:

${MG_{k}} = \frac{{CW_{j}} - {IPW}_{i}}{CW_{j}}$

and wherein each mold gap is independently from about 0.1 to about 0.7;closing the compression mold and compressing the preform into a closedmold cavity; applying heat, pressure, or a combination of both to theclosed mold cavity for a duration of time to: (a) alter at least onepreform dimension in the preform x-axis, y-axis, and z-axis; and (b)alter the closed cell foam structure of the preform to having a greaterproportion of anisotropic cell shape; opening the compression mold afterthe least one preform dimension in the preform x-axis, y-axis, andz-axis and the closed cell foam structure are altered; removing thecompression molded foam article from the compression mold; and forming acompression molded foam article; wherein the compression molded foamarticle retains dimensions of the closed mold cavity within about plusor minus 50 percent; and wherein the compression molded foam article hasthe closed cell foam structure having a greater proportion of closedcells with the anisotropic cell shapes as compared to the preform, orhaving substantially the same proportion of closed cells with theanisotropic cells shapes as compared to the preform, where an averageaspect ratio of the proportion of the closed cells with the anisotropiccell shapes is greater as comparted to the preform, or both theproportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the foam structure of the compression moldedfoam article as compared to the foam structure of the preform.

In a fifth aspect, the present disclosure is directed to methods ofmaking a compression molded foam article, the method comprising:arranging a preform in a compression mold; wherein the preform comprisesa polymeric material having a closed cell foam structure; wherein thepreform is associated with a preform x-axis, y-axis, and z-axis suchthat each axis is perpendicular to the other two; wherein the preformhas a preform longitudinal dimension parallel to the preform y-axis of apreform x-y plan; wherein the preform z-axis is parallel to thedirection of compression applied to the compression mold; wherein thepreform has a preform height that is a dimension parallel to the preformz-axis; wherein the preform has an initial preform height equal to thepreform height prior to compression molding; wherein the preform has apreform volume; and wherein the preform has an initial preform volumethat is the preform volume prior to compression molding; wherein thecompression mold comprises a mold cavity; and wherein the mold cavity isassociated with a mold cavity x-axis, y-axis, and z-axis such that eachaxis is perpendicular to the other two; wherein the mold cavity has alongitudinal dimension parallel to the mold cavity y-axis of a moldcavity x-y plane; wherein the mold cavity z-axis is parallel to thedirection of compression applied to the compression mold; wherein themold cavity has a mold cavity height that is a dimension parallel to thepreform z-axis when the mold is closed; wherein the mold cavity has amold cavity volume associated with the mold when it is closed; whereinthe arranging comprises aligning the preform x-axis, y-axis, and z-axiswith the mold cavity x-axis, y-axis, and z-axis; wherein the initialpreform height is from about 1.1- to about 5-fold greater than the moldcavity height; wherein less than about 90 percent of the mold cavityvolume is occupied by the preform; and wherein at least 30 percent ofthe initial preform volume is positioned outside the mold cavity;closing the compression mold and compressing the preform into a closedmold cavity; applying heat, pressure, or a combination of both to theclosed mold cavity for a duration of time to: (a) alter at least onepreform dimension in the preform x-axis, y-axis, and z-axis; and (b)alter the closed cell foam structure of the preform to having a greaterproportion of anisotropic cell shape; opening the compression mold afterthe least one preform dimension in the preform x-axis, y-axis, andz-axis and the closed cell foam structure are altered; removing thecompression molded foam article from the compression mold; and forming acompression molded foam article; wherein the compression molded foamarticle retains dimensions of the closed mold cavity within about plusor minus 50 percent; and wherein the compression molded foam article hasthe closed cell foam structure having a greater proportion of closedcells with the anisotropic cell shapes as compared to the preform, orhaving substantially the same proportion of closed cells with theanisotropic cells shapes as compared to the preform, where an averageaspect ratio of the proportion of the closed cells with the anisotropiccell shapes is greater as comparted to the preform, or both theproportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the foam structure of the compression moldedfoam article as compared to the foam structure of the preform.

In a sixth aspect, the present disclosure is directed to compressionmolded foam articles made any one of the disclosed methods of the third,fourth, or fifth aspects.

In a seventh aspect, the present disclosure is directed to articlescomprising the compression molded foam article made by any one of thedisclosed methods of the third, fourth, or fifth aspects.

Articles of Footwear.

In various aspects, an article of footwear 10 includes an upper 12, anoptional outsole 14, and a midsole 16. When present, the midsole 16 isoperably secured to both the upper 12 and the outsole 14, and themidsole 16 is disposed between the upper 12 and the outsole 14. Themidsole 16 and the outsole 14 generally extend in transverse directions(i.e., within the X-Y plane) (FIG. 1A), and the midsole 16 and theoutsole 14 each have a thickness defined along a thickness direction(i.e., along the z-axis). In a further aspect, the outsole 14, whenpresent, can be configured such that it does not have the same lengthand width of the midsole 16. That is, the outsole 14, when present, canbe of a width and length such that it contacts portions of theground-facing portion of the midsole 16. In various aspects, the midsole16 comprises materials that are sufficiently abrasion resistant that theground-facing portion thereof does not require a full or partial outsole14. That is, in some aspects, the midsole 16 comprises materials thatare sufficiently abrasion resistant that the ground-facing portionthereof can directly contact the ground during use. It is understood,unless otherwise indicated, that herein throughout like referencenumbers used in one figure refer to like aspects in another figure.

In some aspects, the upper 12 includes various thin sections of materialthat partially overlap each other and that are operably secured to eachother, for example, by stitching, adhesives, and the like. The upper 12defines a cavity in which the wearer's foot is received. The upper 12can also include a fastening structure, such as laces, buckles, and/orother features for tightly securing the upper 12 to the foot of thewearer. It will also be appreciated that the upper 12 can includevarious decorative features. In addition, the upper 12 can have anysuitable shape and/or features that adapt the article of footwear 10 forits intended use.

As shown in FIGS. 1A, 1B, and 2 , the outsole 14 can include a layer ofmaterial that extends in the transverse directions (i.e., within the X-Yplane). The outsole 14 can also have any suitable curvature along thetransverse directions. Additionally, the outsole 14 can have anysuitable thickness (i.e., along the Z-axis), and the thickness of theoutsole 14 can vary in any suitable fashion. Moreover, the outsole 14can include various grooves, projections or other features forincreasing traction of the footwear 10. It will be appreciated that theoutsole 14 can be made out of any suitable material. For instance, theoutsole 14 can include an abrasion-resistant solid or lightly foamedpolymeric material such as rubber. Also, in some aspects, the outsole 14can include a transparent material. Also, it will be appreciated thatthe outsole 14 can vary in material, thickness, function, aesthetics,and the like. Furthermore, in some aspects, the outsole 14 includes anouter periphery 34 that is entirely continuous with the outer peripheryof the midsole 16 (FIGS. 1A, 1B, and 2 , more specifically, as shown inFIG. 1B). In other aspects (not illustrated), the outer periphery of theoutsole 14 is not continuous with the outer periphery of the midsole 16.

As shown hi FIGS. 1A, 18, and 2 , the midsole 16 can include a layer ofmaterial that extends in the transverse directions (i.e., within the X-Yplane). The midsole 16 can also have any suitable curvature along thetransverse directions. Furthermore, the midsole 16 can have any suitablethickness (i.e., along the z-axis), and the thickness of the midsole 16can vary in any suitable fashion. In further aspects, the midsole 16includes an outer periphery 54 that is entirely continuous with theouter periphery of the outsole 14 (FIGS. 1A, 1B, and 2 , morespecifically, as shown in FIG. 1B). It will be appreciated that themidsole 16 can be made out of any suitable material. For instance, themidsole 16 can be made out of any suitable polymeric foam material, suchas ethylene vinyl acetate (EVA) foam, polyamide polymers or co-polymers(PA), styrenic polymers or co-polymers, and/or polyurethane (TPU). Themidsole 16 can also include a material with air pockets or fluid-filledbladders included therein. Additionally, the midsole can includeadditional elements such as a stabilizer or a plate. Also, it will beappreciated that the midsole can vary in material, thickness, function,aesthetics, and the like.

In some aspects, an article of footwear can comprise a sole structure, asole structure component, an upper, an upper component, or anycombination thereof. An upper component refers to a piece that isstitched or otherwise joined with one or more other pieces to form anupper. The materials in the upper generally contribute tocharacteristics such as breathability, conformability, weight, andsuppleness or softness. A sole structure component refers to a piecethat is joined with one or more other pieces to form the lower portionof an article of footwear. The sole structure can include, for example,the outsole and midsole. The choice of outsole materials and design willcontribute, for instance, to the durability, traction, as well as to thepressure distribution during use. The midsole materials and designcontribute to factors such as the cushioning and support. Grinderycomponents include all of the additional components that can be attachedto the upper, sole structure, or both. Grindery components can include,for example, eyelets, toe puffs, shanks, nails, laces, velcro, catches,backers, linings, padding, heel backings, heel foxings, toe caps, etc.

In some aspects, the upper is a lasted upper. A “lasted upper,” as usedherein, refers to an upper that is formed into the shoe shape prior toattachment to the sole by one or more mechanical means. The lasted uppercan include a heel counter formed to shape the heel of the upper. Thelasted upper can include a strobel or a strobel board attached to theupper, typically via a strobel stitch.

Methods of Making Foam Articles Comprising Anisotropic Cell Structure.

In various aspects, the present disclosure pertains to methods formaking compression molded foam articles. The disclosed methods use apreform comprising a polymeric foam material having a closed cell foamstructure to form a compression molded foam article having a closed cellfoam structure with a plurality of cells having an anisotropic cellshape such that either: (a) the compression molded foam article retainsdimensions of the closed mold cavity within about plus or minus 50percent; and (b) wherein the compression molded foam article has theclosed cell foam structure having a greater proportion of closed cellswith the anisotropic cell shapes as compared to the preform, or havingsubstantially the same proportion of closed cells with the anisotropiccells shapes as compared to the preform, where an average aspect ratioof the proportion of the closed cells with the anisotropic cell shapesis greater as comparted to the preform, or both the proportion and theaspect ratio of closed cells with the anisotropic cell shapes aregreater in the foam structure of the compression molded foam article ascompared to the foam structure of the preform. In some instances, theproportion of cells having an anisotropic cell shape is increased in thecompression molded foam article compared to the preform. In furtherinstances, the compression molded foam article can have cells with agreater degree of anisotropic cell shape compared to the preform, e.g.,a greater aspect ratio of a major axis to a minor of the anisotropiccells. In a further aspect, the disclosed methods are capable of using afoam preform having a closed cell foam structure with a substantiallyisotropic cell shape to form a compression molded foam article having aclosed cell foam structure having a substantially anisotropic cellshape.

In various aspects, the proportion of cells having an anisotropic cellshape is increased in the molded foam article compared to the preformwithin a portion of the molded foam article, e.g., within a portion ofthe molded foam article having a volume of at least 1 cubic centimeter,or at least 2 cubic centimeters, or at least 3 cubic centimeters, or atleast 10 percent, or at least 20 percent, or at least 30 percent, or atleast 40 percent, or at least 50 percent of a total volume of the moldedfoam article. In a particular aspect, the proportion of cells having ananisotropic cell shape is increased in the molded foam article comparedto the preform within a portion of the molded foam article that is atleast 1 cubic centimeter.

It is known that molded foam articles, e.g., a compression molded foamarticle, can be associated with a skin localized to the portions of themolded article that are in direct contact with the mold wall. Such askin has substantially no closed cell foam structure. In variousaspects, disclosed molded foam articles have an anisotropiccell-structure in at least a portion of the non-skin portions of themolded foam article, e.g., a distance of about 0.1 millimeters to about2 millimeters from the outside surface of the molded foam article. Insome aspects, disclosed molded foam articles have an anisotropiccell-structure in the non-skin portions of the molded foam article atleast a distance of about 1 millimeters from the outside surface of themolded foam article.

In some aspects, exemplary steps of the disclosed methods are shown inFIGS. 3A, 3B, and 3C, show top plan views at a position marked byreference line 401 shown in FIGS. 4A, 4B and 4C, respectively. Theorientation of a mold cavity x-y plane is shown in each of FIGS. 3A, 3B,and 3C. In the plan views of FIGS. 3A, 3B, and 3C, which are at aposition perpendicular to cross-sectional plan view reference line 401shown in FIGS. 4A-4C, respectively. Accordingly, the mold cavity x-yplane is located at a bottom of the mold cavity, and the top plan viewis shown looking down into a mold cavity opening.

Briefly, referring to FIGS. 3A-3I: FIG. 3A shows a top plan view of arepresentative compression mold for a midsole showing a mold cavitytherein without a foamed preform in the mold cavity (the preform isshown adjacent to the mold); FIG. 3B shows a top plan view of thecompression mold in FIG. 3A with a foamed preform arranged in the moldcavity, prior to compression molding, showing gaps between all contouredperimeter edges generally along the y-axis of the preform and thecontoured boundary of the mold cavity; FIG. 3C shows a top plan view ofthe compression mold in FIG. 3A of the resulting molded foam articleafter compression molding the foam preform, showing that a majority ofthe contoured perimeter of the compression molded foam article is incontact with the contoured boundary of the mold cavity following thecompression molding; FIG. 3D shows a top plan view of a representativecompression mold for a midsole showing a mold cavity therein without afoamed preform in the mold cavity (the preform is shown adjacent to themold); FIG. 3E shows a top plan view of the compression mold in FIG. 3Dwith a foamed preform arranged in the mold cavity, prior to compressionmolding, showing gaps between contoured perimeter edges generally alongthe y-axis in the toe region of the preform and the contoured boundaryof the mold cavity; FIG. 3F shows a top plan view of the compressionmold in FIG. 3D of the resulting compression molded article aftercompression molding the preform, showing that a majority of thecontoured perimeter of the compression molded foam article is in contactwith the contoured boundary of the mold cavity following the compressionmolding; FIG. 3G shows a top plan view of a representative compressionmold for a midsole showing a mold cavity therein without a foamedpreform in the mold cavity (the preform is shown adjacent to the moldwith internal gaps); FIG. 3H shows a top plan view of the compressionmold in FIG. 3G with a foamed preform arranged in the mold cavity, priorto compression molding, showing the preform contoured perimeter is inclose proximity with the contoured boundary of the mold cavity, andfurther shows internal gaps within the preform which oriented lengthwisealong the y-axis of the preform and the contoured boundary of the moldcavity; FIG. 3I shows a top plan view of the compression mold in FIG. 3Gof the resulting molded foam article showing that the internal gaps havebeen compressed and do not exist as gaps after compression molding, andshowing that the majority of the contoured perimeter of the compressionmolded foam article is in contact with the contoured boundary of themold cavity following the compression molding.

Referring now to FIG. 3A in detail, the figure shows a top plan view ofa compression mold, e.g., for a midsole, 100 that is open and comprisesa lower mold component 115 having a mold cavity 110 encompassed by acavity contoured boundary 120. The mold 100 is shown with a widthreference line 101. The mold cavity 110 is associated with a mold cavityarea, which is an area of the mold cavity 110 in an x-y plane as shown.The mold cavity has a mold cavity longitudinal dimension 501 as shown,which is along a line parallel to the y-axis, and represents the longestdimension in the y-axis of the mold cavity. FIG. 3A also shows a foamedpreform 210, prior to compression molding, shown in a position near themold 100, and is shown with the orientation of a foamed preform x-yplane. The preform 210, prior to compression molding is associated withan initial preform area, which is an area of the preform 210, prior tocompression molding, in the preform x-y plane as shown. As shown, thepreform x-y plane and the mold cavity x-y plane are aligned. The preform210, prior to compression molding, is associated with a foamed preforminitial contoured perimeter 220. The preform has a foamed preforminitial longitudinal dimension 502, which is along a line parallel tothe y-axis, and represents the longest dimension in the y-axis of thepreform prior to compression molding.

Referring now to FIG. 3B in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3A with a foamed preform 210, prior tocompression molding, arranged in the mold cavity 110, prior tocompression molding, showing a mold gap of variable dimension extendingbetween the contoured perimeter of a foamed preform 220 and thecontoured boundary of the mold cavity 120. FIG. 3B shows that theinitial preform area is less than the mold cavity area. Thisrelationship of initial preform area to the mold cavity area is alsoapparent in FIG. 3A. The arrangement of the 210, prior to compressionmolding, in the mold cavity 110, is such that the preform x-y plane andthe mold cavity x-y plane are aligned. Moreover, as arranged in FIG. 3B,the mold cavity longitudinal dimension 501, and the preform initiallongitudinal dimension 502, are co-aligned along the same line that isparallel to the y-axis.

Referring now to FIG. 3C in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3A of a foamed preform 230, aftercompression molding, which is associated with a foamed preform finalcontoured perimeter 240. As shown in the figure, the preform 230, aftercompression molding, is associated with a final preform area, which isan area of the preform 230, after compression molding, in the preformx-y plane as shown. In this instance, the final preform area is aboutthe same as the mold cavity area. As shown in FIG. 3C, the preform finalcontoured perimeter 240 is in contact with the mold cavity contouredboundary 120. In some aspects, there can be contact at substantially allpoints along the preform final contoured perimeter 240 and mold cavitycontoured boundary 120. However, in other aspects, a mold gap may existbetween the preform final contoured perimeter 240 at one or more pointsalong the mold cavity contoured boundary 120.

Referring now to FIG. 3D in detail, the figure shows a top plan view ofa compression mold, e.g., for a midsole, 100 that is open and comprisesa lower mold component 115 having a mold cavity 110 encompassed by acavity contoured boundary 120. The mold 100 is shown with a widthreference line 101. The mold cavity 110 is associated with a mold cavityarea, which is an area of the mold cavity 110 in an x-y plane as shown.The mold cavity has a mold cavity longitudinal dimension 501 as shown,which is along a line parallel to the y-axis, and represents the longestdimension in the y-axis of the mold cavity. FIG. 3D also shows a foamedpreform 210, prior to compression molding, shown in a position near themold 100, and is shown with the orientation of a foamed preform x-yplane. The preform 210, prior to compression molding is associated withan initial preform area, which is an area of the preform 210, prior tocompression molding, in the preform x-y plane as shown. As shown, thepreform x-y plane and the mold cavity x-y plane are aligned. The preform210, prior to compression molding, is associated with a foamed preforminitial contoured perimeter 220 a and 220 b. The preform has a foamedpreform initial longitudinal dimension 502, which is along a lineparallel to the y-axis, and represents the longest dimension in they-axis of the preform prior to compression molding.

Referring now to FIG. 3E in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3D with a foamed preform 210, prior tocompression molding, arranged in the mold cavity 110, prior tocompression molding, showing a mold gap of variable dimension extendingbetween the contoured perimeter of a foamed preform 220 a and thecontoured boundary of the mold cavity 120 in the toe region of thepreform and mold. However, in the heel region, the contoured perimeterof the foamed preform 220 b is in close proximity and/or contact withthe contoured boundary of the mold cavity in the heel region of the moldcavity. FIG. 3E shows that the initial preform area in the toe region isless than the mold cavity area in the toe region. This relationship ofinitial preform area to the mold cavity area is also apparent in FIG.3D. The arrangement of the 210, prior to compression molding, in themold cavity 110, is such that the preform x-y plane and the mold cavityx-y plane are aligned. Moreover, as arranged in FIG. 3B, the mold cavitylongitudinal dimension 501, and the preform initial longitudinaldimension 502, are co-aligned along the same line that is parallel tothe y-axis.

Referring now to FIG. 3F in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3D of a compression molded article 230,e.g., a compression molded midsole, which is formed from the preformfollowing compression molding, which is associated with a molded articlecontoured perimeter 240. As shown in the figure, the compression moldedarticle 230, after compression molding, is associated with a finalpreform area, which has an area approximately that or the same as themold cavity in the preform x-y plane as shown. In this instance, thefinal preform area is about the same as the mold cavity area. As shownin FIG. 3F, the preform final contoured perimeter 240 is in contact withthe mold cavity contoured boundary 120. In some aspects, there can becontact at substantially all points along the preform final contouredperimeter 240 and mold cavity contoured boundary 120. However, in otheraspects, a mold gap may exist between the molded article contouredperimeter 240 at one or more points along the mold cavity contouredboundary 120.

Referring now to FIG. 3G in detail, the figure shows a top plan view ofa compression mold, e.g., for a midsole, 100 that is open and comprisesa lower mold component 115 having a mold cavity 110 encompassed by acavity contoured boundary 120. The mold 100 is shown with a widthreference line 101. The mold cavity 110 is associated with a mold cavityarea, which is an area of the mold cavity 110 in an x-y plane as shown.The mold cavity has a mold cavity longitudinal dimension 501 as shown,which is along a line parallel to the y-axis, and represents the longestdimension in the y-axis of the mold cavity. FIG. 3G also shows a foamedpreform 210, prior to compression molding, shown in a position near themold 100, and is shown with the orientation of a foamed preform x-yplane. The foamed preform 210, prior to compression molding isassociated with a plurality of internal gaps 250 a-250 f. The preformhas a foamed preform initial longitudinal dimension 502, which is alonga line parallel to the y-axis, and represents the longest dimension inthe y-axis of the preform prior to compression molding.

Referring now to FIG. 3H in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3G with a foamed preform 210, prior tocompression molding, arranged in the mold cavity 110, prior tocompression molding, that all gaps are internal to the preform. FIG. 3Hshows that the initial preform area in the toe region is less than themold cavity area in the toe region. This relationship of initial preformarea to the mold cavity area is also apparent in FIG. 3G. Thearrangement of the 210, prior to compression molding, in the mold cavity110, is such that the preform x-y plane and the mold cavity x-y planeare aligned. Moreover, as arranged in FIG. 3B, the mold cavitylongitudinal dimension 501, and the preform initial longitudinaldimension 502, are co-aligned along the same line that is parallel tothe y-axis. As shown in FIG. 3H, the contoured perimeter of the foamedpreform 220 and the contoured boundary of the mold cavity 120 are inclose proximity. In some instances, the gap between the foamed preform220 and the contoured boundary of the mold cavity 120 is negligible oressentially absent. In other instances, the gap between the foamedpreform 220 and the contoured boundary of the mold cavity 120 can beabout 0.01 millimeter to about 1 millimeter.

Referring now to FIG. 3I in detail, the figure shows a top plan view ofthe compression mold 100 in FIG. 3G of a compression molded article 230,e.g., a compression molded midsole, which is formed from the preformfollowing compression molding, which is associated with a molded articlecontoured perimeter 240. As shown in the figure, the compression moldedarticle 230, after compression molding, is associated with a finalpreform area, which has an area approximately that or the same as themold cavity in the preform x-y plane as shown. In this instance, thefinal preform area is about the same as the mold cavity area. As shownin FIG. 3I, the preform final contoured perimeter 240 is in contact oressentially in contact with the mold cavity contoured boundary 120. Insome aspects, there can be contact at substantially all points along thepreform final contoured perimeter 240 and mold cavity contoured boundary120. However, in other aspects, a mold gap may exist between the moldedarticle contoured perimeter 240 at one or more points along the moldcavity contoured boundary 120.

In some aspects, exemplary steps of the disclosed methods are shown inFIGS. 4A-4I show cross-sectional plan views at a position marked byreference line 101 shown in FIGS. 3A-3I, respectively, and FIGS. 4J-40show cross-sectional plan views at a position marked by reference line102 shown in FIGS. 3J-3R, respectively. The orientation of a mold cavityx-z plane is shown in each of FIGS. 4A-4I, and the orientation of a moldcavity y-z plane is shown in each of FIGS. 4J-40 .

Referring now to FIG. 4A in detail, the figure shows a cross-sectionalplan view of a compression mold 100 that is open and comprises a lowermold component 115 having a mold cavity 110 encompassed by a cavitycontoured boundary 120 and an upper mold component 105. The upper moldcomponent 105 fits within the lower mold component 115 (as shown in FIG.4C) when the mold is closed. The outside edges of the upper moldcomponent 105 can fit flush with the inner edges of the lower moldcomponent 115. In other aspects, a small gap may exist between theoutside edges of the upper mold component 105 can fit flush with theinner edges of the lower mold component 115, with the gap being of adimension of 0.01 millimeter to about several millimeters. The mold 100is shown with a width reference line 401. Prior to closing the mold, theupper mold component 105 can be placed atop the preform 210, as shown inFIG. 4B. The mold is understood to be closed when the upper moldcomponent 105 is arranged in the lower mold component 115 to a desiredposition, e.g., such that an outer edge of the upper mold component 105is flush with an upper edge of the lower mold component 115 as shown inFIG. 4C. FIGS. 4J-4L show the mold 100 in the y-z plane corresponding toFIGS. 4A-4C, respectively.

The mold cavity has a mold cavity height dimension 503 as shown, whichis along a line parallel to the z-axis, and represents the height at aparticular position along the mold cavity longitudinal dimension 501. Insome instances, the mold cavity height dimension 503 can beapproximately uniform as determined at various positions along the moldcavity longitudinal dimension 501. However, in other instances, the moldcavity height dimension 503 can comprise a plurality of mold cavityheight dimensions comprising individual mold cavity height dimensions,each individual mold cavity height dimension associated with aparticular position along the mold cavity longitudinal dimension 501. Insome aspects, the individual mold cavity height dimensions can vary fromone another. The plurality of mold cavity height dimensions can beassociated with an average mold cavity height dimension which is thenumber weighted average of individual mold cavity height dimensionsdetermined along the mold cavity longitudinal dimension 501.

FIG. 4A also shows a unitary foamed preform 210, prior to compressionmolding, with the orientation of a foamed preform x-z plane shown. Thepreform has an initial preform height dimension 504 as shown, which isalong a line parallel to the z-axis, and represents the height at aparticular position along the mold cavity longitudinal dimension 501. Insome instances, the initial preform height dimension 504 can beapproximately uniform as determined at various positions along the moldcavity longitudinal dimension 501. However, in other instances, theinitial preform height dimension 504 can comprise a plurality of initialpreform height dimensions comprising individual initial preform heightdimensions, each initial preform height dimension associated with aparticular position along the mold cavity longitudinal dimension 501. Insome aspects, the individual initial preform height dimensions can varyfrom one another. The plurality of initial preform height dimensions canbe associated with an average initial preform height dimension which isthe number weighted average of individual initial preform heightdimensions determined along the mold cavity longitudinal dimension 501.The preform 210, prior to compression molding, is associated with afoamed preform initial contoured perimeter 220.

As shown in FIGS. 4A, 4B, and 4C, the mold 100 is further associatedwith a movable platen assembly 300 comprising a movable platencompression member 310 and a movable platen extendable member 320,which, as shown in FIGS. 4A, 4B, and 4C, can extend to contact the uppermold component outside edges of the upper mold component 105 can fitflush with the inner edges of the upper mold component 105, therebymoving the movable platen compression member 310 and the upper moldcomponent 105 in a direction of movement 330 parallel to the z-axis. Asshown in FIGS. 4A, 4B, and 4C, the movable platen extendable member 320is shown at different positions as follows: in a position in which themovable platen extendable member 320 a such that the mold is open (FIG.4A); in a position in which the movable platen extendable member 320 bsuch that the mold is still open, but in which the movable platencompression member 310 is closer to the preform 210, prior tocompression molding (FIG. 4B); and); in a position in which the movableplaten extendable member 320 c such that the mold is closed with themovable platen compression member 310 essentially in contact with a topsurface of the mold 100, thereby compressing the preform to the preform230, after compression molding (FIG. 4C). The direction of movement 330of the movable platen compression member 310 is in a direction in whichcompression is applied to the mold 100.

Referring now to FIG. 4B, the figure shows a cross-sectional plan viewof the compression mold 100 in FIG. 4A with a foamed preform 210, priorto compression molding, arranged in the mold cavity 110, prior tocompression molding, showing a mold gap extending between the contouredperimeter of a foamed preform 220 and the contoured boundary of the moldcavity 120. FIG. 4B shows that a width dimension of the preform 210,prior to compression molding, along a dimension parallel to the x-axisis less than a mold cavity width along a dimension parallel to thex-axis. The arrangement of the 210, prior to compression molding, in themold cavity 110, is such that the preform x-z plane and the mold cavityx-z plane are aligned. Moreover, as arranged in FIG. 4B, the mold cavitylongitudinal dimension 501, and the preform initial longitudinaldimension 502, are co-aligned along the same line that is parallel tothe y-axis.

Referring now to FIG. 4C, the figure shows a cross-sectional view of thecompression mold 100 in FIG. 4A of a foamed preform 230, aftercompression molding, which is associated with a foamed preform finalcontoured perimeter 240. FIG. 4C shows that a width dimension of thepreform 230, prior to compression molding, along a dimension parallel tothe x-axis is about the same as the mold cavity width along a dimensionparallel to the x-axis. As shown in FIG. 4C, the preform final contouredperimeter 240 is in contact with the mold cavity contoured boundary 120.In some aspects, there can be contact at substantially all points alongthe preform final contoured perimeter 240 and mold cavity contouredboundary 120. However, in other aspects, a mold gap may exist betweenthe preform final contoured perimeter 240 at one or more points alongthe mold cavity contoured boundary 120.

FIG. 4C also shows a foamed preform 230, after compression molding, withthe orientation of a foamed preform x-z plane shown. The preform has afinal preform height dimension 505 as shown, which is along a lineparallel to the z-axis, and represents the height at a particularposition along the mold cavity longitudinal dimension 501. In someinstances, the final preform height dimension 505 can be approximatelyuniform as determined at various positions along the mold cavitylongitudinal dimension 501. However, in other instances, the finalpreform height dimension 505 can comprise a plurality of final preformheight dimensions comprising individual final preform height dimensions,each final preform height dimension associated with a particularposition along the mold cavity longitudinal dimension 501. In someaspects, the individual final preform height dimensions can vary fromone another. The plurality of final preform height dimensions can beassociated with an average final preform height dimension which is thenumber weighted average of individual final preform height dimensionsdetermined along the mold cavity longitudinal dimension 501.

Referring now to FIG. 4D, the figure shows a cross-sectional plan viewof a compression mold 100 that is open and comprises a lower moldcomponent 115 having a mold cavity 110 encompassed by a cavity contouredboundary 120 and an upper mold component 105. The upper mold component105 fits within the lower mold component 115 (as shown in FIG. 4C) whenthe mold is closed. The outside edges of the upper mold component 105can fit flush with the inner edges of the lower mold component 115. Inother aspects, a small gap may exist between the outside edges of theupper mold component 105 can fit flush with the inner edges of the lowermold component 115, with the gap being of a dimension of 0.01 millimeterto about several millimeters. The mold 100 is shown with a widthreference line 401. Prior to closing the mold, the upper mold component105 can be placed atop the preform 210, as shown in FIG. 4E. The mold isunderstood to be closed when the upper mold component 105 is arranged inthe lower mold component 115 to a desired position, e.g., such that anouter edge of the upper mold component 105 is flush with an upper edgeof the lower mold component 115 as shown in FIG. 4F.

The mold cavity has a mold cavity height dimension 503 as shown, whichis along a line parallel to the z-axis, and represents the height at aparticular position along the mold cavity longitudinal dimension 501. Insome instances, the mold cavity height dimension 503 can beapproximately uniform as determined at various positions along the moldcavity longitudinal dimension 501. However, in other instances, the moldcavity height dimension 503 can comprise a plurality of mold cavityheight dimensions comprising individual mold cavity height dimensions,each individual mold cavity height dimension associated with aparticular position along the mold cavity longitudinal dimension 501. Insome aspects, the individual mold cavity height dimensions can vary fromone another. The plurality of mold cavity height dimensions can beassociated with an average mold cavity height dimension which is thenumber weighted average of individual mold cavity height dimensionsdetermined along the mold cavity longitudinal dimension 501.

FIG. 4E also shows a stacked foam preform comprising a first foampreform 270, a sheet 260, and a second foam preform 280, prior tocompression molding, with the orientation of a foamed preform x-z planeshown. In some instances, the sheet 260 is not present (as shown in FIG.4P), and the stacked foam preform comprises a first foam preform and asecond foam preform, respectively, as 270 and 280. Similarly, as shownin FIG. 4S, a split foam preform can be utilized comprising a first foampreform 270, a sheet 260, and a second foam preform 280, and arrangedrelative to one another as shown therein. It is understood that thefirst foam preform 270 and the second foam preform 280, in any of theconfigurations as shown in FIG. 4D, 4P, or 4S, can be the same orsimilar in cell density and/or preform density using the same or similarpolymers. Alternatively, each of the first foam preform 270 and thesecond foam preform 280 can independently be distinct from one anotherin cell density, preform density, and polymer composition. In variousfurther aspects, each of the first foam preform 270 and the second foampreform 280 can be of any desirable shape such as wedge, rectangular, orirregular when viewed in either a top plan view or cross-sectional viewin the y-z plane or in the x-z plane.

The preform has a stacked foam preform initial height dimension 520 asshown, which is along a line parallel to the z-axis, and represents theheight at a particular position along the mold cavity longitudinaldimension 501. The initial stacked foam preform height dimension 520 isthe sum of the first foam preform initial height dimension 530, thethickness of the mesh 260, and the second foam preform initial heightdimension 540. In some instances, the stacked foam preform initialheight dimension 520 can be approximately uniform as determined atvarious positions along the mold cavity longitudinal dimension 501.However, in other instances, the initial stacked foam preform heightdimension 520 can comprise a plurality of initial preform heightdimensions comprising individual initial preform height dimensions, eachinitial preform height dimension associated with a particular positionalong the mold cavity longitudinal dimension 501. In some aspects, theindividual initial preform height dimensions can vary from one another.The plurality of initial preform height dimensions can be associatedwith an average initial preform height dimension which is the numberweighted average of individual initial preform height dimensionsdetermined along the mold cavity longitudinal dimension 501. The firstfoam preform 270 and the second foam preform 280, prior to compressionmolding, are associated with a foam preform initial contoured perimeter223 and 224, respectively.

As shown in FIGS. 4D, 4E, and 4F, the mold 100 is further associatedwith a movable platen assembly 300 comprising a movable platencompression member 310 and a movable platen extendable member 320,which, as shown in FIGS. 4D, 4E, and 4F, can extend to contact the uppermold component outside edges of the upper mold component 105 can fitflush with the inner edges of the upper mold component 105, therebymoving the movable platen compression member 310 and the upper moldcomponent 105 in a direction of movement 330 parallel to the z-axis. Asshown in FIGS. 4D, 4E, and 4F, the movable platen extendable member 320is shown at different positions as follows: in a position in which themovable platen extendable member 320 a such that the mold is open (FIG.4D); in a position in which the movable platen extendable member 320 bsuch that the mold is still open, but in which the movable platencompression member 310 is closer to the preform 210, prior tocompression molding (FIG. 4E); and); in a position in which the movableplaten extendable member 320 c such that the mold is closed with themovable platen compression member 310 essentially in contact with a topsurface of the mold 100, thereby compressing the preform to the preform230, after compression molding (FIG. 4F). The direction of movement 330of the movable platen compression member 310 is in a direction in whichcompression is applied to the mold 100.

Referring now to FIG. 4E, the figure shows a cross-sectional plan viewof the compression mold 100 in FIG. 4D with a stacked foam preformcomprising a first foam preform 270, a sheet 260, and a second foampreform 280, prior to compression molding, arranged in the mold cavity110, prior to compression molding, showing a mold gap extending betweenthe contoured perimeter first foam preform 270 and the second foampreform 280, i.e., a foam preform initial contoured perimeter 223 and224, respectively, and the contoured boundary of the mold cavity 120.FIG. 4E shows that a width dimension of the stacked foam preform, priorto compression molding, along a dimension parallel to the x-axis is lessthan a mold cavity width along a dimension parallel to the x-axis. Thearrangement of the stacked foam preform, prior to compression molding,in the mold cavity 110, is such that the preform x-z plane and the moldcavity x-z plane are aligned. Moreover, as arranged in FIG. 4E, the moldcavity longitudinal dimension 501, and the preform initial longitudinaldimension 502, are co-aligned along the same line that is parallel tothe y-axis.

Referring now to FIG. 4F, the figure shows a cross-sectional view of thecompression mold 100 in FIG. 4A of a stacked molded article, aftercompression molding, comprising a first molded article 272, e.g., afirst molded midsole, and a second molded article 282, e.g., a secondmolded midsole, and a sheet 260 located between the first molded articleand the second molded article, and which a first molded articlecontoured perimeter 223 and a second molded article contoured perimeter224. FIG. 4F shows that a width dimension of the stacked molded articlealong a dimension parallel to the x-axis is about the same as the moldcavity width along a dimension parallel to the x-axis. As shown in FIG.4F, the molded article contoured perimeter comprising the first moldedarticle contoured perimeter 223 and the second molded article contouredperimeter 224 is in contact or essentially in contact with the moldcavity contoured boundary 120. In some aspects, there can be contact atsubstantially all points along the molded article contoured perimeterand mold cavity contoured boundary 120. However, in other aspects, amold gap may exist between the molded article contoured perimeter at oneor more points along the mold cavity contoured boundary 120.

FIG. 4F also shows a stacked molded article, after compression molding,comprising a first molded article 272, e.g., a first molded midsole, anda second molded article 282, e.g., a second molded midsole, and a sheet260 located between the first molded article and the second moldedarticle with the orientation of a foamed preform x-z plane shown. Thepreform has a molded article height dimension 522 as shown, which isalong a line parallel to the z-axis, and represents the height at aparticular position along the mold cavity longitudinal dimension 501.The molded article height dimension 522 is a sum of the first moldedarticle height dimension 532, the thickness of the mesh 260, and thesecond molded article height dimension 542. In some instances, themolded article height dimension 522 can be approximately uniform asdetermined at various positions along the mold cavity longitudinaldimension 501. However, in other instances, the molded article heightdimension 522 can comprise a plurality of final preform heightdimensions comprising individual final preform height dimensions, eachfinal preform height dimension associated with a particular positionalong the mold cavity longitudinal dimension 501. In some aspects, theindividual final preform height dimensions can vary from one another.The plurality of final preform height dimensions can be associated withan average final preform height dimension which is the number weightedaverage of individual final preform height dimensions determined alongthe mold cavity longitudinal dimension 501.

FIGS. 4G-4I are similar to FIGS. 4A-4C, except that the upper moldcomponent 105 and the lower mold component 115 are shown with a curvedshape in the x-z plane. Similarly, the foam preform can have a similarcurved shape in the x-z plane as shown. In other instances, the foampreform can be essentially flat on the upper and lower edges (as shownin FIG. 4A), and a shape can be obtained from compression molding with acurved upper mold component 105 and a curved lower mold component 115 asshown in FIGS. 4G-4I. FIGS. 4M-40 show the mold 100 in the y-z planecorresponding to FIGS. 4G-4I, respectively.

FIGS. 4P-4R are similar to FIGS. 4A-4C, except that as shown in FIG. 4P,two preforms, i.e., a first preform and a second preform, are used andare stacked upon one on top of the other. That is, the method furthercomprises arranged a second preform on top of a first preform, with themethod optionally comprising placing an adhesive on the first preform,on the second preform, or both the first and second preforms prior toarranging the second preform on top of it. Noteworthy is that as insituation where a single preform is used, such as described for FIGS.4A-4C, there is a gap between the preform perimeter, as defined by thecombination of the first and second preforms, and the mold wall. Theprocess is otherwise as described for FIGS. 4A-4C. As noted above, anadhesive can be placed between the two preforms. However, in someaspects, no adhesive is placed between the first and the secondpreforms, but they become affixed to one another during the compressionmolding process as a result of at least partial softening of the firstpreform, the second preform, or both, and the melted preform flowing tothe other, thereby at least partially affixing the first preform to thesecond preform. As can be appreciated, the method as discussed herein ismerely one example. That is, it is not limited to just use of a firstand second preform, but rather it is contemplated that a plurality ofpreforms of varying thicknesses could be arranged one on top of theother in an analogous manner.

FIGS. 4S-4U are similar to FIGS. 4A-4C, except that as shown in FIG. 4S,two preforms, i.e., a first preform and a second preform, are used andare arranged side-by-side as shown in FIG. 4S. That is, the methodfurther comprises arranged a second preform alongside a first preform,with the method optionally comprising placing an adhesive on the firstpreform, on the second preform, or both the first and second preformsprior to arranging the second preform alongside of it. Noteworthy isthat as in situation where a single preform is used, such as describedfor FIGS. 4A-4C, there is a gap between the preform perimeter, asdefined by the combination of the first and second preforms, and themold wall. The process is otherwise as described for FIGS. 4A-4C. Asnoted above, an adhesive can be placed between the two preforms.However, in some aspects, no adhesive is placed between the first andthe second preforms, but they become affixed to one another during thecompression molding process as a result of at least partial softening ofthe first preform, the second preform, or both, and the melted preformflowing to the other, thereby at least partially affixing the firstpreform to the second preform. As can be appreciated, the method asdiscussed herein is merely one example. That is, it is not limited tojust use of a first and second preform, but rather it is contemplatedthat a plurality of preforms of varying thicknesses could be arrangedside-by-side in an analogous manner.

FIGS. 4V-4X are similar to FIGS. 4J-4L, except that as shown in FIG. 4V,a preform is used that has two height dimensions over the length of thepreform. This can be obtained in a unitary or single preform by moldingas such, or alternatively, cutting or shaping a uniform preform have asubstantially similar height dimension as shown in FIG. 4J.Alternatively, a preform having two heights as shown can be obtained byarranging a second preform on top of a first preform, or arranging ashorter height dimension first preform alongside of a higher heightdimension preform as variation of the methods described immediatelyabove for FIGS. 4P-4R and FIGS. 4S-4U. As can be appreciated,compression of a stepped preform as shown in FIG. 4V, can providedistinct properties associated with each portion of differing heightdimensions including different degrees of anisotropy, density, and thelike, or differences in combinations of these properties. As can beappreciated, the method as discussed herein is merely one example. Thatis, it is not limited to just utilizing a preform having two differentheight dimensions, but rather it is contemplated that a preform having aplurality of height dimensions can be utilized in an analogous manner.

In various aspects, a mold 100 having a mold cavity 110 and a moldcavity wall 115 can comprise one or a plurality of microvents arrangedin the mold cavity wall 115, such that each microvent has an opening offrom about 10 micrometers to about 500 micrometers.

The sheet 260 can be a film or a textile such as a mesh textile, and canbe a single sheet or a plurality of sheets, e.g., a plurality of filmsand/or mesh textiles arranged in layers. In some implementations, themidsole structure includes a plurality of sheets disposed between thefirst midsole portion and the second midsole portion. The plurality ofsheets may include two or more sheets 260 positioned between a medialside of the midsole structure and a lateral side of the midsolestructure. A width of each of the two or more sheets may be at least 0.5cm. At least a portion of the plurality of sheets disposed between thefirst midsole portion and the second midsole portion may partially orfully overlap each other in a region between the first midsole portionand the second midsole portion. Optionally, none of the plurality ofsheets 260 disposed between the first midsole portion and the secondmidsole portion may overlap each other in a region between the firstmidsole portion and the second midsole portion.

In some configurations, the midsole structure includes an adhesivedisposed between the first midsole portion and the second midsoleportion. The adhesive may be applied to at least one of the firstmidsole portion, the second midsole portion, an upper surface of thesheet 260, and a lower surface of the sheet 260. The sheet 260 mayinclude at least one aperture. For example, the sheet may include a meshtextile including at least one aperture in a structure of the mesh orincluding a plurality of apertures in a structure of the mesh. A regionof the sheet disposed between the first midsole portion and the secondmidsole portion may include at least 50 apertures in the structure ofthe sheet. The sheet 260 may further include a plurality of apertureseach being at least 0.5 mm in length in a largest dimension or at least1.0 mm in length in a largest dimension. The sheet 260 may also includea plurality of apertures each being less than 10 mm in length in alargest dimension, each being less than 5.0 mm in length in a largestdimension, or each being less than 3.0 mm in length in a largestdimension. Additionally or alternatively, the sheet 260 may include aplurality of apertures each having a length in a largest dimension fromabout 0.5 mm to about 3.0 mm.

In some implementations, the sheet 260 is configured to stretch in inonly one dimension, such as a textile configured to stretch in only onedimension. Optionally, the sheet 260 may be configured to stretch in twodimensions. The sheet 260 may be an embroidered sheet, such as anembroidered textile. The sheet 260 may include embroidered regionsdisposed at discrete locations of the sheet 260. The sheet 260 may alsoinclude first embroidered regions and second embroidered regions. Thefirst embroidered regions may have a different concentration of fibersthan the second embroidered regions.

In some configurations the sheet 260 includes a textile such as a woventextile, a knit textile, a crocheted textile, a braided textile, anon-woven textile, or any combination thereof. The sheet 260 can includeat least one of a woven textile and a knitted textile. The method mayalso include providing an adhesive between the first midsole portion andthe second midsole portion. The method may further include bonding thefirst midsole portion, the second midsole portion, and the sheet 260together via the adhesive. Optionally, the method may include forming atleast one of the first midsole portion and the second midsole portionfrom a foamed material. In some instances, the sheet 260 is a textilethat is a mesh. In various aspects, the sheet 260 is a film, such as aflexible film.

The sheet 260 may be formed from a polymeric material such as, forexample, a thermoplastic polymeric material. An exemplary thermoplasticpolymeric material may include, for example, a thermoplasticpolyurethane or the like. In some examples, the sheet 260 may be athermoformable material. In some examples, if the sheet 260 is atextile, the textile can comprise polyester fibers. Furthermore, inother examples, if the sheet 260 is a textile including apertures suchas a mesh textile, each aperture of the sheet 260 may be at least 0.5 mmin length in a largest dimension or at least 1.0 mm in length in alargest dimension. Furthermore, each aperture formed in the sheet 260may be configured to permit one or both of the first midsole portion andthe second midsole portion to directly contact one another. In variousaspects, the sheet 260 includes a polymeric material comprising one ormore polymers, such as a polyurethane, a polyurea, a polyamide, apolyester, a polyether, a polyolefin, and any combination thereof. Theone or more polymers can include a block copolymer of ethylene andα-olefins having 4 to about 8 carbon atoms, a styrene block copolymersuch as poly(styrene-butadiene-styrene),poly(styrene-ethylene-co-butylene-styrene), andpoly(styrene-isoprene-styrene), and combinations thereof.

In some instances, the sheet 260 is an embroidered sheet, such as anembroidered textile, and has one or more first regions includingembroidery and one or more second regions without embroidery or with alower percentage of embroidered surface area as comparted to the one ormore first regions. The embroidery can provide reduced stretch or a“lock down” feature to areas of the sheet 260. Such areas of the sheet260 providing a reduced stretch quality may be located, for example, ata region of the sheet 260 that is arranged between the first midsoleportion and the second midsole portion.

A compression ratio can be associated with the disclosed methods, suchthat the compression ratio is the ratio of initial preform heightdimension 504 to the final preform height dimension 505. In variousaspects, the compression ratio can be a ratio from about 1.1 to about10.0, or about 1.2 to about 4.0, or about 1.5 to about 3.0.

Referring now to FIGS. 5A and 5B, further views of the mold gap areshown. Referring to FIG. 5A, a top plan view width reference line 101 ais shown at a particular position, P₁, along a longitudinal cavitydimension line 102. The longitudinal cavity dimension line 102 isparallel to the y-axis of the mold x-y plane as shown. As shown, thepreform 210, prior to compression molding, has an initial preform width,IPW₁, 602 a along the top plan view width reference line 101 a. Further,as shown, the mold cavity 110 has mold cavity width, CW₁, 603 a alongthe top plan view width reference line 101 a. In this instance, theinitial preform width, IPW₁, 602 a is less than the mold cavity width,CW₁, 603 a at the top plan view width reference line 101 a. In FIG. 5A,the preform 210, prior to compression molding, is arranged in the moldcavity 110 such they are each co-aligned in the y-axis along thelongitudinal cavity dimension line 102. That is, the preform 210, priorto compression molding, is approximately centered in the mold cavity 110in the y-axis. As a result of the particular alignment of the preform210, prior to compression molding, and the mold cavity 110, there existtwo mold gaps, 601 a and 601 a′, along the top plan view width referenceline 101 a between the preform initial contoured perimeter 220 and themold cavity contoured boundary 120 as shown. In some aspects, as shown,the mold gaps, 601 a and 601 a′, can have different dimensions. In otheraspects, the mold gaps, 601 a and 601 a′, can be of equal dimensions.

Referring to FIG. 5B, a top plan view width reference line 101 b isshown at a particular position, P₂, along a longitudinal cavitydimension line 102. The longitudinal cavity dimension line 102 isparallel to the y-axis of the mold x-y plane as shown. As shown, thepreform 210, prior to compression molding, has an initial preform width,IPW₂, 602 b along the top plan view width reference line 101 b. Further,as shown, the mold cavity 110 has mold cavity width, CW₂, 603 b alongthe top plan view width reference line 101 b. In this instance, theinitial preform width, IPW₂, 602 b is less than the mold cavity width,CW₂, 603 b at the top plan view width reference line 101 a. In FIG. 5B,the preform 210, prior to compression molding, is arranged in the moldcavity 110 such they are each co-aligned in the y-axis along thelongitudinal cavity dimension line 102. That is, the preform 210, priorto compression molding, is approximately centered in the mold cavity 110in the y-axis. As a result of the particular alignment of the preform210, prior to compression molding, and the mold cavity 110, there existtwo mold gaps, 601 b and 601 b′, along the top plan view width referenceline 101 b between the preform initial contoured perimeter 220 and themold cavity contoured boundary 120 as shown. In some aspects, as shown,the mold gaps, 601 b and 601 b′, can have different dimensions. In otheraspects, the mold gaps, 601 b and 601 b′, can be of equal dimensions.

Referring now to FIGS. 5C and 5C, further views of the mold gap areshown. Referring to FIG. 5C, a top plan view width reference line 101 ais shown at a particular position, P₁, along a longitudinal cavitydimension line 102. The longitudinal cavity dimension line 102 isparallel to the y-axis of the mold x-y plane as shown. As shown, thepreform 210, prior to compression molding, has an initial preform width,IPW₁, 602 a along the top plan view width reference line 101 a. Further,as shown, the mold cavity 110 has mold cavity width, CW₁, 603 a alongthe top plan view width reference line 101 a. In this instance, theinitial preform width, IPW₁, 602 a is less than the mold cavity width,CW₁, 603 a at the top plan view width reference line 101 a. In FIG. 5A,the preform 210, prior to compression molding, is arranged in the moldcavity 110 such they are each co-aligned in the y-axis along thelongitudinal cavity dimension line 102. That is, the preform 210, priorto compression molding, is approximately centered in the mold cavity 110in the y-axis. As a result of the particular alignment of the preform210, prior to compression molding, and the mold cavity 110, there existtwo mold gaps, 601 a and 601 a′, along the top plan view width referenceline 101 a between the preform initial contoured perimeter 220 and themold cavity contoured boundary 120 as shown. In some aspects, as shown,the mold gaps, 601 a and 601 a′, can have different dimensions. In otheraspects, the mold gaps, 601 a and 601 a′, can be of equal dimensions. Asshown in FIG. 5C, there are essentially no or negligible gaps betweenthe foamed preform and the mold cavity contoured boundary 120 in theheel region of the foamed preform and the mold cavity.

Referring to FIG. 5D, a top plan view width reference line 101 b isshown at a particular position, P₂, along a longitudinal cavitydimension line 102. The longitudinal cavity dimension line 102 isparallel to the y-axis of the mold x-y plane as shown. As shown, thepreform 210, prior to compression molding, has an initial preform width,IPW₂, 602 b along the top plan view width reference line 101 b. Further,as shown, the mold cavity 110 has mold cavity width, CW₂, 603 b alongthe top plan view width reference line 101 b. In this instance, theinitial preform width, IPW₂, 602 b is less than the mold cavity width,CW₂, 603 b at the top plan view width reference line 101 a. In FIG. 50 ,the preform 210, prior to compression molding, is arranged in the moldcavity 110 such they are each co-aligned in the y-axis along thelongitudinal cavity dimension line 102. That is, the preform 210, priorto compression molding, is approximately centered in the mold cavity 110in the y-axis. As a result of the particular alignment of the preform210, prior to compression molding, and the mold cavity 110, there existtwo mold gaps, 601 b and 601 b′, along the top plan view width referenceline 101 b between the preform initial contoured perimeter 220 and themold cavity contoured boundary 120 as shown. In some aspects, as shown,the mold gaps, 601 b and 601 b′, can have different dimensions. In otheraspects, the mold gaps, 601 b and 601 b′, can be of equal dimensions. Asshown in FIG. 5D, there are essentially no or negligible gaps betweenthe foamed preform and the mold cavity contoured boundary 120 in theheel region of the foamed preform and the mold cavity.

In a further aspect, a plurality of mold gaps can exist between a foamedpreform 210, prior to compression molding, and a mold cavity 110. Thatis, a plurality of initial preform widths comprise a number ofindividual initial preform width, such as IPW₁, IPW₂ . . . IPW_(i),where i is an integer less than 100, each associated with a particularposition, P₁, P₂ . . . P_(i), along a longitudinal cavity dimension line102. Corresponding to each individual initial preform width, such asIPW₁, IPW₂ . . . IPW_(i) is an associated individual cavity widths, suchas CW₁, CW₂ . . . CW_(i), where j is an integer less than 100, eachassociated with a particular position, P₁, P₂ . . . P_(i), along alongitudinal cavity dimension line 102. The plurality of mold gapscomprise individual mold gaps, MG₁, MG₂ . . . MG_(k), where k is aninteger less than 100, each associated with a particular position, P₁,P₂ . . . P_(i), along a longitudinal cavity dimension line 102. That is,each mold gap, MG_(k), is obtained from the following equation:

${MG_{k}} = \frac{{CW}_{j} - {IPW}_{i}}{{CW}_{j}}$

and wherein each mold gap is independently from about 0.1 to about 0.7.In a further aspect, each mold gap, MG_(k), is independently about 0.125to about 0.625, each mold gap, MG_(k), is independently about 0.150 toabout 0.625, each mold gap, MG_(k), is independently about 0.200 toabout 0.625, each mold gap, MG_(k), is independently about 0.225 toabout 0.625, each mold gap, MG_(k), is independently about 0.250 toabout 0.625, each mold gap, MG_(k), is independently about 0.300 toabout 0.625. each mold gap, MG_(k), is independently about 0.325 toabout 0.625, each mold gap, MG_(k), is independently about 0.400 toabout 0.625, each mold gap, MG_(k), is independently about 0.500 toabout 0.625, a value or combination of values within any of theforegoing ranges, or a sub-range of any of the foregoing ranges. In astill further aspect, the plurality of mold gaps comprise a mold gap,MG_(k), having a value that is about equal to a value of a mold gap,MG_(k+1), a value that is independently different from a value of a moldgap, MG_(k+1), or combinations thereof. In a yet further aspect, theplurality of mold gaps comprise individual mold gaps that areindependently different from one another, substantially equal to oneanother, or combinations thereof. In various aspects, each MG_(k) canindependently have a different value. In a further aspect, each MG_(k)is about the same value.

In some instances, when the disclosed methods are used to prepare amidsole with anisotropic cell structure, that the mold gap can taper toessentially zero in regions proximal to the toe and heel area of thefoamed preform and mold. That is, the mold gap is such that a limitedportion (e.g., less than about 0.1 centimeter to about 1 centimeter) ofthe toe tip and the heel end of the preform contact the sides of themold after the preform is placed in the mold.

In can be appreciated that the mold gap (MG) can be substantially aroundthe entire perimeter of the preform. In some aspects, the mold gap (MG)that is substantially around the entire perimeter of the preform isabout 0.1 centimeters, 0.2 centimeters, 0.3 centimeters, 0.4centimeters, 0.5 centimeters, 0.6 centimeters, 0.7 centimeters, 0.8centimeters, 0.9 centimeters, 1.0 centimeter; any combination of theforegoing gap values; or a range encompassed by any of the foregoing gapvalues. In a further aspect, the mold gap (MG) can be around about atleast about 10 percent, 20 percent, 30 percent, 40 percent, 50 percent,60 percent, 70 percent, 80 percent, or 90 percent of the perimeter ofthe preform. In a still further aspect, mold gap (MG) of about 0.5 cmcan be around about at least about 10 percent, 20 percent, 30 percent,40 percent, 50 percent, 60 percent, 70 percent, 80 percent, or 90percent of the perimeter of the preform.

In other aspects, the gap is an internal gap as shown in FIG. 3G. Thatis, as shown in FIG. 3G, there can be a plurality of internal gapslocated more or less uniformly within an x-y plane of a preform.Alternatively, the internal gaps can be located or clustered within aparticular region of the x-y plane of the preform, e.g., clusteredwithin the toe region or the heel region. It is understood that a singleinternal gap may be desired instead of a plurality of internal gaps. Theone or more internal gaps can be associated with an internal gap volume,i.e., the gap is defined as having created a gap of a certain volumewithin the preform. The internal gap volume can be about at least about0.1 cubic centimeters, 0.2 cubic centimeters, 0.3 cubic centimeters, 0.4cubic centimeters, 0.5 cubic centimeters, 0.6 cubic centimeters, 0.7cubic centimeters, 0.8 cubic centimeters, 0.9 cubic centimeters, 1.0cubic centimeters; any combination of the foregoing internal gapvolumes, or a range of internal gap volumes encompassed by any two ofthe foregoing internal gap volumes.

Referring now to FIGS. 6A and 6B, top plan views are provided of acompression mold 1000 and a foamed preform 910, e.g., a plaque mold anda plaque foamed preform, in the x-y plane. As shown in FIG. 6A, thepreform 910, prior to compression molding, has a uniform initial preformwidth 701 and a uniform initial preform length 702. Further, as shown,the mold cavity 1010 has a uniform mold cavity width 801 and a uniformmold cavity length 802. The cavity 1010 is contained by a mold wall1015. The foamed preform is associated with a preform initial contouredperimeter 920, and the mold cavity is associated with a mold cavitycontoured boundary 1020. In FIG. 6B, the preform 910, prior tocompression molding, is arranged in the mold cavity 1010 such they areeach co-aligned in the y-axis along the longitudinal cavity dimensionline 802. That is, the preform 910, prior to compression molding, isapproximately centered in the mold cavity 1010 along the y-axis. As aresult of the particular alignment of the preform 910, prior tocompression molding, and the mold cavity 1010, there exist a uniformmold gap along the top plan view between the preform initial contouredperimeter 920 and the mold cavity contoured boundary 1020 as shown. Insome aspects, as shown, the mold gaps, 802 a and 802 b, can havedifferent dimensions. In other aspects, the mold gaps, 802 a and 802 b,can be of equal dimensions. Alternatively or additionally, the preformcan include one or more apertures as described above (not illustrated).Alternatively or additionally, the preform can be a single piece offoam, or can be two or more separate pieces of foam, as described above(not illustrated). Referring to FIG. 6C, a top plan view is shown of thecompression mold 1000 with a molded article 911 contained in the moldcavity 1010. The molded article 911 is associated with a molded articlecontoured perimeter 921 that is in contact or essentially in contactwith the mold cavity contoured boundary 1020. As shown, the moldedarticle width 703 of the molded article 911, after compression molding,is substantially the same as the mold cavity width 801.

In some examples, the compression molding process is conducted byheating the foam preform in a closed compression mold. The foam preformis heated to a temperature close to its softening temperature, to allowthe foam to retain the shape of the compression mold. For example, thefoam preform can be heated to a temperature within plus or minus 30degrees Celsius of its softening temperature, or within plus or minus 20degrees Celsius of its softening temperature, or within plus or minus 10degrees Celsius of its softening temperature, or within plus or minus 5degrees Celsius of its softening temperature. For example, the foampreform can be heated to a temperature of from about 100 degrees Celsiusto about 250 degrees Celsius, from about 140 degrees Celsius to about220 degrees Celsius, from about 100 degrees Celsius to about 180 degreesCelsius, from about 150 degrees Celsius to about 180 degrees Celsius, orfrom about 130 degrees Celsius to about 180 degrees Celsius

The material used to form the compression mold can be any material whichcan withstand the temperatures used during the process, such as machinedmetals, including aluminum. The compression mold can be made using twopieces, such as a top and a bottom mold. Depending on the shape of thefoam component to be molded, a multiple-piece mold may be used in orderto more easily release the compression molded foam article from themold.

The compression molding of the foam preform in the compression mold canresult in a skin forming on the final compression molded foam component.However, care should be taken during the compression molding not tosubject the foam preform to conditions such that more than a desiredamount of the closed cell structures of the foam collapse. One way toavoid collapsing more than a desired amount of the closed cellstructures is to control the temperature of the polymeric composition,for example, by controlling the temperature of the mold. For example,during the compression molding step, the heating of the foam preform inthe compression mold can be conducted for time of from 100 seconds to1,000 seconds, or of from 150 seconds to 700 seconds.

Once the foam preform has been heated in the compression mold at theappropriate temperature for the desired length of time to soften thepreform to the desired level, the softened preform is cooled, forexample, to a temperature at least 35 degrees Celsius below itssoftening temperature or below the highest temperature the preformreached in the closed mold (its maximum molding temperature), or atleast 50 degrees Celsius below its softening or maximum moldingtemperature, or at least 80 degrees Celsius below its softening ormaximum molding temperature, to re-solidify the softened foam orstabilize the molded foam, thereby forming the compression molded foam.Once cooled, the compression molded foam article is removed from thecompression mold. Following the heating, the cooling of the molded foamin the compression mold can be conducted for a time of from 50 to 1,000seconds, or for a time of from 100 to 400 seconds.

In various aspects, the disclosed methods directed to a compressionmolded foam article (e.g., articles used to make at least portions offootwear or athletic equipment) can further comprise a step of making afoamed preform. The foamed preform can be made using processes such ascutting the foam preform from foam sheet, or injection molding a foammaterial to form the foam preform, extruding a foam material to form thefoam preform, expanding a material to form the foam perform, and thelike.

In various aspects, a compression molded foam article can be acompression molded foam cushioning element, and can be used as a midsolecomponent or as a midsole-outsole unit, e.g., a midsole componentattached to a separate outsole if the foamed material used in themidsole is not suitable for use as a ground-contacting foam.Alternatively, a disclosed midsole component or midsole can be used canbe used without an outsole if the foamed material of the side of themidsole that is configured to be ground-facing is suitable for use as aground-contacting foam.

Also, a disclosed midsole or midsole component can be used as a core ina core-carrier midsole, or as a drop-in, i.e., in an article of footwearin which there is an outsole but there isn't a strobel separating themidsole from the foot cavity of the upper, and accordingly the midsolecan be positioned into a cavity in the outsole through the foot cavity.For example, the present disclosure contemplates a sole assemblycomprising a shell and an insert as generally described in U.S. Pat. No.8,769,843, which is incorporated herein in its entirety. As such theshell, the insert, or both can be a compression molded foam article asdescribed herein.

It is further contemplated herein, that when a disclosed midsole ormidsole component is utilized in a core-carrier-type sole structure,optionally, the compression molding step of the method can be performedin the carrier. That is, instead of placing a foamed preform directly incontact with the bottom and sides of a mold cavity, a carrier can firstbe placed into the mold cavity and then the preform placed inside thecarrier. Thus, in lieu of a mold gap there is a carrier gap between theinner sides of the carrier and the foamed preform. Accordingly, once themold is closed (contacting the top of the preform), this variant of thedisclosed methods compression molds the foamed preform to fill thecarrier.

It may be desirable in some circumstances that the foamed preform usedin the disclosed methods is aged. That is, following blowing of thefoam, the foam is allowed to equilibrate at ambient temperature andpressure for a suitable period of time, e.g., about 12 hours to about 60days. Without wishing to be bound by a particular theory, it ispossible, for example, in circumstances such the foamed preform wasprepared using a blowing agent that generated gas, aging the foam mayallow some of the gas in the cells to partition out and otheratmospheric gasses to partition in. Further, without wishing to be boundby a particular theory, it is possible, for example, that aging permitsthe pressure of the gas in the cells to partially dissipate. In certainaspects, the disclosed methods can further comprise subjecting thepreform to an annealing step or a foam stabilization step or both priorto arranging the foam preform in the mold cavity. Similarly, in certainaspects, the disclosed methods can further comprise subjecting thecompression molded foam article to an annealing step or a foamstabilization step or both.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatan order be inferred, in any respect. This holds for any possiblenon-express basis for interpretation, including: matters of logic withrespect to arrangement of steps or operational flow; plain meaningderived from grammatical organization or punctuation; and the number ortype of aspects described in the specification.

Molded Foam Articles.

In various aspects, the disclosed molded foam articles exhibitanisotropic physical properties, such as energy return or stiffness.That is, the physical property can have a distinct property along oneaxis of the molded foam article compared to one or both of the otheraxes.

In some aspects, a physical property can be anisotropic in a disclosedmolded foam article or a molded foam article made using the disclosedmethods compared to the same physical property of a conventionallymolded foam article having a closed cell structure having asubstantially isotropic or isotropic closed cell foam structure. Whilemolded foam articles formed from conventional methods may havesatisfactory physical properties, the disclosed molded foam articlesuniquely provide an anisotropic physical properties along one axis ofthe molded foam article compared to one or both of the other axes. Incontrast, conventionally molded foam articles are characterized byproperties that are generally isotropic along all three axes of themolded foam article.

In some aspects, the energy return of a disclosed molded foam articlehaving anisotropic closed cell structure as disclosed herein or a moldedfoam article made using the disclosed methods can be can be greater thanthe energy return of the otherwise same molded foam article having aclosed cell structure having a substantially isotropic or isotropic cellshape. While molded foam articles formed from conventional methods mayhave satisfactory stiffness, the disclosed molded foam articles uniquelyprovide an anisotropic energy return properties along one axis of themolded foam article compared to one or both of the other axes. Incontrast, conventionally molded foam articles are characterized byenergy return properties that are generally isotropic along all threeaxes of the molded foam article.

In some instances, the anisotropic physical property of a disclosedmolded foam article can be changed, e.g., increased, compared to thepreform within a particular portion of the molded foam article, e.g.,within a region having a volume of at least 1 cubic centimeter, or atleast 2 cubic centimeters, or at least 3 cubic centimeters; or at least10 percent, 20 percent, 30 percent, 40 percent, or 50 percent of a totalvolume of the molded foam article. In a particular aspect, theanisotropic physical property is changed in the molded foam articlecompared to the preform within a within a region having a volume of atleast 1 cubic centimeter.

It is known that molded foam articles, e.g., a compression molded foamarticle, can be associated with a skin localized to the portions of themolded article that are in direct contact with the mold wall. Such askin has substantially no closed cell foam structure. In variousaspects, disclosed molded foam articles have an anisotropic physicalproperty in the non-skin portions of the molded foam article, e.g., adistance of about 0.1 millimeters to about 2 millimeters from theoutside surface of the molded foam article. In some aspects, disclosedmolded foam articles have an anisotropic physical property in thenon-skin portions of the molded foam article a distance of about 1millimeters from the outside surface of the molded foam article.

In various aspects, the disclosed molded foam articles and molded foamarticles prepared by the disclosed methods can exhibit a differencealong a first axis, e.g., the z-axis, compared to the same physicalproperty determined along a second axis and/or a third axis, e.g., thex-axis and y-axis, respectively. In a further aspect, the difference inthe physical property along the first axis can differ from the samephysical property along the second axis and/or third axis by at leastabout 5 percent, 10 percent, 15 percent, or 20 percent.

The disclosed molded foam articles and molded foam articles prepared bythe disclosed methods can exhibit a beneficial energy return, e.g., anenergy return in the z-axis such as the energy return for a midsolecomponent along a z-axis oriented as shown in FIG. 1A. In variousaspects, the disclosed molded foam articles exhibit an energy return,when determined in accordance with Efficiency Test Method, in the z-axisof greater than about 60 percent, about 65 percent, about 70 percent,about 75 percent, about 80 percent, greater than about 82 percent,greater than about 84 percent, greater than about 86 percent, greaterthan about 88 percent, or greater than about 92 percent. In a furtheraspect, the disclosed molded foam articles exhibit an energy return,when determined in accordance with test referred to herein throughout asthe Efficiency Test Method, in the z-axis of from about 80 percent toabout 92 percent, of from about 82 percent to about 92 percent, of fromabout 84 percent to about 92 percent, of from about 86 percent to about92 percent, of from about 88 percent to about 92 percent, a value or setof values within any of the foregoing ranges, or a sub-range of any ofthe foregoing ranges.

In various aspects, the disclosed molded foam articles and molded foamarticles prepared by the disclosed methods can exhibit an energy returnin the z-axis that is about 4 percent to about 100 percent higher than areference foam article, wherein the reference foam article is a foamarticle having a substantially same density as the foam article; andwherein the reference foam article has a closed cell structure that issubstantially isotropic.

In various aspects, the disclosed molded foam articles and molded foamarticles prepared by the disclosed methods can exhibit an energy returnin the z-axis that is about 4 percent to about 150 percent greater thanthe energy return in the x-axis and/or y-axis of the molded foamarticle.

In various aspects, the stiffness of the molded foam article can be lessthan the stiffness of a similar molded foam article comprising aplurality of cells having a substantially isotropic or isotropic cellshape.

The molded foam articles described herein can exhibit a beneficialstiffness, for example a stiffness for a midsole component along az-axis oriented as shown in FIG. 1A. The stiffness can be measured asdescribed herein. In some aspects, the disclosed molded foam article canhave a stiffness value, when determined in accordance with EfficiencyTest Method, in the z-axis of the molded foam article from about 300kilopascals to about 2000 kilopascals, about 300 kilopascals to about600 kilopascals, about 300 kilopascals to about 550 kilopascals, about300 kilopascals to about 400 kilopascals, a value or group values withinany of the foregoing ranges, or a sub-range of any of the foregoingranges.

In a further aspect, the disclosed molded foam articles can beassociated with additional physical properties. For example, split tearis an important physical property for a foam used as a cushioningelement, such as in a component of an article of footwear or athleticequipment. In some aspects, the molded foam article can have a splittear value of from about 4.0 kilograms per centimeter to 10 kilogramsper centimeter, from about 1.0 kilograms per centimeter to 4.5 kilogramsper centimeter, about 1.6 kilograms per centimeter to 4.0 kilograms percentimeter, about 2.0 kilograms per centimeter to 4.0 kilograms percentimeter, about 2.0 kilograms per centimeter to 3.5 kilograms percentimeter, or about 2.5 kilograms per centimeter to 3.5 kilograms percentimeter. The split tear can be measured as described in the examplesbelow. In some aspects, the molded foam article can have a split tear ofabout 0.08 kilograms per centimeter to 4.0 kilograms per centimeter,about 0.9 kilograms per centimeter to 3.0 kilograms per centimeter,about 1.0 to 2.0 kilograms per centimeter, about 1.0 kilograms percentimeter to 1.5 kilograms per centimeter, or about 2 kilograms percentimeter. In some aspects, the molded foam article can have a splittear of about 0.07 kilograms per centimeter to 2.0 kilograms percentimeter, or about 0.8 kilograms per centimeter to 1.5 kilograms percentimeter, or about 0.9 kilograms per centimeter to 1.2 kilograms percentimeter, about 1.5 kilograms per centimeter to 2.2 kilograms percentimeter.

Split tear for foam preforms and molded foam articles can be measuredusing ASTM D3574-95. Although this method is directed to bonded andmolded urethane foams, it can be used on any foam material in accordancewith the present disclosure. A sample of foam having a thickness of 10millimeter plus or minus 1 millimeter is used. If the foam preform ormolded foam article has an outer skin, the outer skin should not bepresent on the test sample. A 3 centimeter long cut is placed in thecenter of one end of the specimen, and marked in five successive 2centimeter portions along the edge of the sample. The sample is testedas described in ASTM D3574-95.

In various aspects, the disclosed molded foam articles and molded foamarticles made using the disclosed methods have an article density offrom about 0.10 grams per cubic centimeter to about 0.35 grams per cubiccentimeter, from about 0.11 grams per cubic centimeter to about 0.12grams per cubic centimeter, or from about 0.10 grams per cubiccentimeter to about 0.12 grams per cubic centimeter, from about 0.15grams per cubic centimeter to about 0.20 grams per cubic centimeter;from about 0.15 grams per cubic centimeter to about 0.30 grams per cubiccentimeter; a combination of the foregoing values; a value within theforegoing value; or a sub-range within the foregoing ranges.

Durometer is another important physical property of a foam. Inaccordance with the present disclosure, the molded foam article has adurometer of at least 20 Asker C, or at least 30 Asker C, or at least 40Asker C, or at least 50 Asker C For example, the durometer of the moldedfoam article can be from 20 Asker C to 70 Asker C, or from 20 Asker C to40 Asker C, or from 30 Asker C to 35 Asker C, or from 25 Asker C to 65Asker C, or from 30 Asker C to 50 Asker C, or from 40 Asker C to 70Asker C, or from 35 Asker C to 55 Asker C, or from 50 Asker C to 65Asker C The foam preform can have a durometer of less than 40 Asker C,or less than 30 Asker C, or less than 20 Asker C. For example, thedurometer of the foam preform can be from 15 Asker C to 50 Asker C, orfrom 20 Asker C to 50 Asker C, or from 20 Asker C to 40 Asker C, or from20 Asker C to 30 Asker C. The durometer is measured on a flat area offoam, e.g., at least 6 millimeter thick, using an Asker C durometer.

Another physical property of the disclosed molded foam articles is its300 percent elongation. The molded foam article can have an elongationof at least 125 kilograms per centimeter, or at least 150 kilograms percentimeter.

In various aspects, the disclosed molded foam articles comprise a closedcell foam structure. In a further aspect, the disclosed methods forforming the disclosed molded foam articles comprise a step of arranginga foamed preform in a compression mold. The preform arranged in thecompression mold preform has a closed cell foam structure.

Polymeric Materials.

As such, the disclosed molded foam articles and the preform used in thedisclosed methods of making comprise molded foam article comprise one ormore polymers which have been foamed. In some aspects, the one or morepolymers can be one or more elastomeric polymers. In further aspects,the one or more polymers can be one or more thermoplastic polymers. Instill further aspects, the one or more polymers can be one or morethermoplastic elastomeric polymers. In yet further aspects, the one ormore polymers can be one or more cross-linked polymers.

In various aspects, the polymer can be a polyolefin polymer, e.g., anethylene-vinyl-acetate (EVA) polymer. The polyolefin polymer can be apolymer comprising styrene repeating units and non-styrenic repeatingunits; a C₄-C₁₀₀ unsaturated olefin; an ethylene vinyl acetatecopolymer; an olefin block copolymer; and mixtures thereof. In someaspects, a polyolefin polymer is an A-B-A block copolymer, wherein eachof the A blocks have styrenic repeat units, the B block is a randomcopolymer of ethylene and a first alpha-olefin having 3 to 8 carbonatoms (e.g. 3, 4, 5, 6, 7, or 8 carbon atoms), and wherein theA-B-A-block copolymer includes about 10 percent to 50 percent, about 10percent to 40 percent, about 15 percent to 40 percent, or about 15percent to 30 percent of the A blocks by weight based upon an entireweight of the A-B-A block copolymer; an olefinic block copolymer,wherein the olefinic block copolymer is a copolymer of ethylene and asecond alpha-olefin having about 4 to 14, about 6 to 12, or about 6 to10 carbon atoms, and wherein the olefinic block copolymer has one ormore blocks rich in the ethylene and one or more blocks rich in thesecond alpha-olefin; and an ethylene-vinyl acetate copolymer.

Elastomeric ethylene-vinyl acetate copolymers can be prepared byfree-radical emulsion polymerization of ethylene and up to about 50percent by weight vinyl acetate. The vinyl acetate monomer is usually atleast about 10 percent by weight, preferably at least about 25 percentby weight of the monomers used. The ethylene-vinyl acetate copolymer hasa vinyl acetate content of preferably from about 25 weight percent toabout 50 weight percent and more preferably from about 35 weight percentto about 50 weight percent. The ethylene-vinyl acetate (EVA) copolymercan have a vinyl acetate content of about 5 percent to 55 percent, about5 percent to 50 percent, about 10 percent to 50 percent, about 10percent to 45 percent, or about 15 percent to 40 percent by weight basedupon the weight of the ethylene-vinyl acetate copolymer. Theethylene-vinyl acetate copolymers may have a melt flow index of fromabout 0.5 to about 50 grams/10 min. (at 190 degrees C., 2.16 kg),preferably 2.5 to 10 grams/10 min. (at 190 degrees C., 2.16 kg) asmeasured using the procedure of ASTM D1238. Nonlimiting examples ofsuitable commercially available ethylene-vinyl acetate copolymersinclude ELVAX 265, ELVAX 40L-3 from DuPont (Midland, Mich., USA) andLAVAPRENE 400 from Langxess (Cologne, Germany). The ethylene-vinylacetate copolymers may be used in combination. In some aspects, the EVAmay be formed of a combination of high melt index and low melt indexmaterial. For example, the EVA may have a melt index betweenapproximately 1 and approximately 50.

In further aspects, the polyolefin polymers can be homopolymers of vinylesters and olefin-vinyl ester copolymers, such as polyvinyl acetate,ethylene-vinyl acetatecopolymers and propylene-vinyl acetate copolymers,may be used as the vinyl ester polymer.

In various aspects, the polymer can be a block copolymer comprising afirst block and a third block, each independently comprising a linear orbranched chain aliphatic polymer having a plurality of aromatic groupsattached pendently thereto, a second block located between the firstblock and the third block and comprising an aliphatic polymer having aplurality of aliphatic side chains attached thereto, and a plurality offirst ethylenically unsaturated group present on one or more of thefirst block, second block, and third block; wherein the block copolymercomprises about 60 percent to about 90 percent of the second blocks byweight based upon the weight of the block copolymer; an olefiniccopolymer comprising a plurality of first olefinic segments and aplurality of second olefinic segments having a different chemicalstructure from the first olefinic segments; one or more linkingpolymers, each linking polymer comprising one or more third olefinicsegments; and an ethylene-vinyl acetate (EVA) copolymer; wherein a sumof a ratio I, II, III, IV, and V is from about 1.00 to about 10.00;wherein the ratio I is a ratio of a total parts by weight of theolefinic copolymers present in the composition to a total parts byweight of the block copolymer present in the composition; wherein theratio II is a ratio of a total parts by weight of the linking polymerspresent in the composition to a total parts by weight of the blockcopolymer present in the composition; wherein the ratio III is ratio ofa total parts by weight of the EVA copolymers present in the compositionto a total parts by weight of the block copolymer present in thecomposition; wherein the ratio IV is a ratio of the total parts byweight of the linking polymers present in the composition to a totalparts by weight of the block copolymers present in the composition, andwherein the ratio V is a ratio of the total parts by weight of the oneor more EVA copolymers present in the composition to a total parts byweight of the one or more olefinic copolymers present in thecomposition.

In various aspects, the polymer can be a block copolymer comprising afirst block and a third block, each independently comprising a linear orbranched chain aliphatic polymer having a plurality of aromatic groupsattached pendently thereto, a second block located between the firstblock and the third block and comprising an aliphatic polymer having aplurality of aliphatic side chains attached thereto, and a plurality offirst ethylenically unsaturated group present on one or more of thefirst block, second block, and third block; wherein the block copolymercomprises about 60 percent to about 90 percent of the second blocks byweight based upon the weight of the block copolymer; an olefiniccopolymer comprising a plurality of first olefinic segments and aplurality of second olefinic segments having a different chemicalstructure from the first olefinic segments; and one or more linkingpolymers, each linking polymer comprising one or more third olefinicsegments.

In various aspects, the polymer can be a composition comprising an A-B-Ablock copolymer, wherein each of the A blocks comprise styrenic repeatunits, the B block is a random copolymer of ethylene and an alpha-olefinhaving about 3 to 8 carbon atoms, and wherein the A-B-A-block copolymercomprises about 10 percent to about 40 percent of the A blocks by weightbased upon the weight of the A-B-A block copolymer; an olefinic blockcopolymer, wherein the olefinic block copolymer is a copolymer ofethylene and an alpha-olefin having about 6 to 12 carbon atoms, andwherein the olefinic block copolymer has one or more blocks rich in theethylene and one or more blocks rich in the alpha-olefin; analpha-olefin linking polymer, wherein the alpha-olefin linking polymeris a copolymer of ethylene and an alpha-olefin having about 3 to 8carbon atoms, and wherein the alpha-olefin linking polymer has analpha-olefin monomer content of about 15 percent to about 40 percent byweight based upon the weight of the alpha-olefin linking polymer; and anethylene-vinyl acetate copolymer having a vinyl acetate content of about10 percent to about 40 percent by weight based upon the weight of theethylene-vinyl acetate copolymer.

In various aspects, the polymer can be a composition comprising apartially hydrogenated thermoplastic elastomeric block copolymer, thepartially hydrogenated thermoplastic elastomeric block copolymercomprising: one or more A blocks comprising aromatic repeat units, oneor more B blocks comprising aliphatic repeat units, and one or morefirst ethylenically unsaturated groups present on one or both of thearomatic repeat units and the aliphatic repeat units; an olefinic blockcopolymer, wherein the olefinic block copolymer is a copolymer of afirst alpha-olefin and a second alpha-olefin different from the firstalpha-olefin, and wherein the olefinic block copolymer comprising one ormore second ethylenically unsaturated groups; an alpha-olefin linkingpolymer, wherein the alpha-olefin linking polymer comprises one or morealiphatic sidechains; and an ethylene-vinyl acetate copolymer; wherein asum of a ratio I, II, III, IV, and V is from about 1.00 to about 10.00;wherein the ratio I is a ratio of a total parts by weight of theolefinic copolymers present in the composition to a total parts byweight of the partially hydrogenated thermoplastic elastomeric blockcopolymer present in the composition; wherein the ratio II is a ratio ofa total parts by weight of the alpha-olefin linking polymers present inthe composition to a total parts by weight of the partially hydrogenatedthermoplastic elastomeric block copolymer present in the composition;wherein the ratio III is ratio of a total parts by weight of theethylene-vinyl acetate copolymers present in the composition to a totalparts by weight of the partially hydrogenated thermoplastic elastomericblock copolymer present in the composition; wherein the ratio IV is aratio of the total parts by weight of the alpha-olefin linking polymerspresent in the composition to a total parts by weight of the partiallyhydrogenated thermoplastic elastomeric block copolymer present in thecomposition, and wherein the ratio V is a ratio of the total parts byweight of the one or more ethylene-vinyl acetate copolymers present inthe composition to a total parts by weight of the one or more olefiniccopolymers present in the composition.

In various aspects, the polymer can be a composition comprising: apartially hydrogenated thermoplastic elastomeric block copolymer, thepartially hydrogenated thermoplastic elastomeric block copolymercomprising: one or more A blocks comprising aromatic repeat units, oneor more B blocks comprising aliphatic repeat units, and one or morefirst ethylenically unsaturated groups present on one or both of thearomatic repeat units and the aliphatic repeat units; an olefinic blockcopolymer, wherein the olefinic block copolymer is a copolymer of afirst alpha-olefin and a second alpha-olefin different from the firstalpha-olefin, and wherein the olefinic block copolymer comprising one ormore second ethylenically unsaturated groups; an alpha-olefin linkingpolymer, wherein the alpha-olefin linking polymer comprises one or morealiphatic sidechains; and an ethylene-vinyl acetate copolymer.

In various aspects, the polymer can be a composition comprising one ormore partially hydrogenated thermoplastic elastomeric block copolymers,each of the one or more partially hydrogenated thermoplastic elastomericblock copolymers independently comprising one or more aromatic blocks,one or more aliphatic blocks, and one or more first ethylenicallyunsaturated units; one or more olefinic block copolymers, each of theone or more olefinic block copolymers comprising second ethylenicallyunsaturated units; one or more alpha-olefin linking polymers; and one ormore ethylene-vinyl acetate copolymers; wherein a sum of a ratio I, II,III, IV, and V is from about 1.00 to about 10.00; wherein the ratio I isa ratio of a total parts by weight of the olefinic block copolymerspresent in the composition to a total parts by weight of the partiallyhydrogenated thermoplastic elastomeric block copolymer present in thecomposition; wherein the ratio II is a ratio of a total parts by weightof the alpha-olefin linking polymers present in the composition to atotal parts by weight of the partially hydrogenated thermoplasticelastomeric block copolymer present in the composition; wherein theratio III is ratio of a total parts by weight of the ethylene-vinylacetate copolymers present in the composition to a total parts by weightof the partially hydrogenated thermoplastic elastomeric block copolymerpresent in the composition; wherein the ratio IV is a ratio of the totalparts by weight of the alpha-olefin linking polymers present in thecomposition to a total parts by weight of the partially hydrogenatedthermoplastic elastomeric block copolymer present in the composition,and wherein the ratio V is a ratio of the total parts by weight of theone or more ethylene-vinyl acetate copolymers present in the compositionto a total parts by weight of the one or more olefinic copolymerspresent in the composition.

In various aspects, the polymer can be a composition comprising one ormore partially hydrogenated thermoplastic elastomeric block copolymers,each of the one or more partially hydrogenated thermoplastic elastomericblock copolymers independently comprising one or more aromatic blocks,one or more aliphatic blocks, and one or more first ethylenicallyunsaturated units; one or more olefinic block copolymers, each of theone or more olefinic block copolymers comprising second ethylenicallyunsaturated units; one or more alpha-olefin linking copolymers; and oneor more ethylene-vinyl acetate copolymers.

In various aspects, the polymer can be a one or more thermoplasticcopolyester elastomers. The thermoplastic copolyester elastomers caninclude chain units derived from one or more olefins and chain unitsderived from one or more ethylenically-unsaturated acid groups. Thecompositions can also include a plurality of cations ionicallycrosslinking anionic forms of the acid groups in the thermoplasticcopolyester elastomers. In some aspects, the thermoplastic copolyesterelastomers can have a melt flow index of about 30 or less, about 20 orless, about 15 or less, about 10 or less, or about 5 or less.

In some aspects, the thermoplastic copolyester elastomers areterpolymers of ethylene, acrylic acid, and methyl acrylate or butylacrylate. In some aspects, a ratio III of a total parts by weight of theacrylic acid in the thermoplastic copolyester elastomers to a totalweight of the thermoplastic copolyester elastomers is about 0.05 toabout 0.6, about 0.1 to about 0.6, about 0.1 to about 0.5, about 0.15 toabout 0.5, or about 0.2 to about 0.5.

The thermoplastic copolyester elastomer can comprise: (a) a plurality offirst segments, each first segment derived from a dihydroxy-terminatedpolydiol; (b) a plurality of second segments, each second segmentderived from a diol; and (c) a plurality of third segments, each thirdsegment derived from an aromatic dicarboxylic acid. In various aspects,the thermoplastic copolyester elastomer is a block copolymer. In someaspects, the thermoplastic copolyester elastomer is a segmentedcopolymer. In further aspects, the thermoplastic copolyester elastomeris a random copolymer. In still further aspects, the thermoplasticcopolyester elastomer is a condensation copolymer.

In a further aspect, the thermoplastic copolyester elastomer can have aweight average molecular weight of about 50,000 Daltons to about1,000,000 Daltons; about 50,000 Daltons to about 500,000 Daltons; about75,000 Daltons to about 300,000 Daltons; about 100,000 Daltons to about200,000 Daltons; or a value or values of weight average molecular weightwithin any of the foregoing ranges or a weight average molecular weightrange encompassing any sub-range of the foregoing ranges.

In a further aspect, the thermoplastic copolyester elastomer can have aratio of first segments to third segments from about 1:1 to about 1:5based on the weight of each of the first segments and the thirdsegments; about 1:1 to about 1:3 based on the weight of each of thefirst segments and the third segments; about 1:1 to about 1:2 based onthe weight of each of the first segments and the third segments; about1:1 to about 1:3 based on the weight of each of the first segments andthe third segments; or a value or values of have a ratio of firstsegments to third segments within any of the foregoing ranges or a havea range of ratio of first segments to third segments encompassing anysub-range of the foregoing ranges.

In a further aspect, the thermoplastic copolyester elastomer can a ratioof second segments to third segments from about 1:1 to about 1:2 basedon the weight of each of the first segments and the third segments;about 1:1 to about 1:1.52 based on the weight of each of the firstsegments and the third segment; or a value or values of have a ratio ofsecond segments to third segments within any of the foregoing ranges ora have a range of ratio of second segments to third segmentsencompassing any sub-range of the foregoing ranges.

In a further aspect, the thermoplastic copolyester elastomer can havefirst segments derived from a poly(alkylene oxide)diol having anumber-average molecular weight of about 250 Daltons to about 6000Daltons; about 400 Daltons to about 6,000 Daltons; about 350 Daltons toabout 5,000 Daltons; about 500 Daltons to about 3,000 Daltons; or avalue or values of weight average molecular weight within any of theforegoing ranges or a weight average molecular weight range encompassingany sub-range of the foregoing ranges.

In a further aspect, the thermoplastic copolyester elastomer can havefirst segments derived from a poly(alkylene oxide)diol such aspoly(ethylene ether)diol; poly(propylene ether)diol; poly(tetramethyleneether)diol; poly(pentamethylene ether)diol; poly(hexamethyleneether)diol; poly(heptamethylene ether)diol; poly(octamethyleneether)diol; poly(nonamethylene ether)diol; poly(decamethyleneether)diol; or mixtures thereof. In a still further aspect, thethermoplastic copolyester elastomer can have first segments derived froma poly(alkylene oxide)diol such as poly(ethylene ether)diol;poly(propylene ether)diol; poly(tetramethylene ether)diol;poly(pentamethylene ether)diol; poly(hexamethylene ether)diol. In a yetfurther aspect, the thermoplastic copolyester elastomer can have firstsegments derived from a poly(tetramethylene ether)diol.

In a further aspect, the thermoplastic copolyester elastomer can havesecond segments derived from a diol having a molecular weight of lessthan about 250. The diol from which the second segments are derived canbe a C2-C8 diol. In a still further aspect, the second segments can bederived from ethanediol; propanediol; butanediol; pentanediol; 2-methylpropanediol; 2,2-dimethyl propanediol; hexanediol; 1,2-dihydroxycyclohexane; 1,3-dihydroxy cyclohexane; 1,4-dihydroxy cyclohexane; andmixtures thereof. In a yet further aspect, the second segments can bederived from 1,2-ethanediol, 1,3-propanediol, 1,4-butanediol,1,6-hexanediol, and mixtures thereof. In an even further aspect, thesecond segments can be derived from 1,2-ethanediol. In a still furtheraspect, the second segments can be derived from 1,4-butanediol.

In a further aspect, the thermoplastic copolyester elastomer can havethird segments derived from an aromatic C5-C16 dicarboxylic acid. Thearomatic C5-C16 dicarboxylic acid can have a molecular weight less thanabout 300 Daltons; about 120 Daltons to about 200 Daltons; or a value orvalues of molecular weight within any of the foregoing ranges or amolecular weight range encompassing any sub-range of the foregoingranges. In some instances, the aromatic C5-C16 dicarboxylic acid isterephthalic acid, phthalic acid, isophthalic acid, or a derivativethereof. In a still further aspect, the aromatic C5-C16 dicarboxylicacid is a diester derivative of the terephthalic acid, phthalic acid, orisophthalic acid. In a yet further aspect, the aromatic C5-C16dicarboxylic acid is terephthalic acid or the dimethyl ester derivativethereof.

In some aspects, the thermoplastic copolyester elastomer used cancomprise: (a) a plurality of first segments, each first segment derivedfrom a dihydroxy-terminated polydiol; (b) a plurality of secondsegments, each second segment derived from a diol; and (c) a pluralityof third segments, each third segment derived from an aromaticdicarboxylic acid.

In a further aspect, the thermoplastic copolyester elastomer used cancomprise: (a) a plurality of first copolyester units, each firstcopolyester unit of the plurality comprising the first segment derivedfrom a dihydroxy-terminated polydiol and the third segment derived froman aromatic dicarboxylic acid, wherein the first copolyester unit has astructure represented by a formula:

wherein R₁ is a group remaining after removal of terminal hydroxylgroups from the poly(alkylene oxide) diol of the first segment, whereinthe poly(alkylene oxide) diol of the first segment is a poly(alkyleneoxide) diol having a number-average molecular weight of about 400 toabout 6000; and wherein R₂ is a group remaining after removal ofcarboxyl groups from the aromatic dicarboxylic acid of the thirdsegment; and (b) a plurality of second copolyester units, each secondcopolyester unit of the plurality comprising the second segment derivedfrom a diol and the third segment derived from an aromatic dicarboxylicacid, wherein the second copolyester unit has a structure represented bya formula:

wherein R₃ is a group remaining after removal of hydroxyl groups fromthe diol of the second segment derived from a diol, wherein the diol isa diol having a molecular weight of less than about 250; and wherein R₂is the group remaining after removal of carboxyl groups from thearomatic dicarboxylic acid of the third segment.

In some aspects, the first copolyester unit has a structure representedby a formula:

wherein R is H or methyl; wherein y is an integer having a value from 1to 10; wherein z is an integer having a value from 2 to 60; and whereina weight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Inthe foregoing, y can an integer having a value of 1, 2, 3, 4, or 5. Insome aspects, in the foregoing, R is hydrogen; R is methyl; R ishydrogen and y is an integer having a value of 1, 2, or 3; or R ismethyl and y is an integer having a value of 1.

In some aspects, the first copolyester unit has a structure representedby a formula:

wherein z is an integer having a value from 2 to 60; and wherein aweight average molecular weight of each of the plurality of firstcopolyester units is from about 300 Daltons to about 7,000 Daltons. Inthe foregoing, z can be an integer having a value from 5 to 60. In someaspects, the weight average molecular weight of each of the plurality offirst copolyester units is from about 400 Daltons to about 6,000Daltons.

In some aspects, the second copolyester unit has a structure representedby a formula:

wherein x is an integer having a value from 1 to 20. In some aspects, xis an integer having a value from 2 to 18.

In various aspects, the thermoplastic copolyester elastomer comprisesabout 30 weight percent to about 80 weight percent of the plurality offirst copolyester units based on total weight of the thermoplasticcopolyester elastomer; or in alternative aspects, about 40 weightpercent to about 65 weight percent of the plurality of secondcopolyester units based on total weight of the thermoplastic copolyesterelastomer.

In an aspect, the thermoplastic copolyester elastomer has a ratio offirst segments to third segments from about 1:1 to about 1:5 based onthe weight of each of the first segments and the third segments; orwherein the thermoplastic copolyester elastomer has a ratio of secondsegments to third segments from about 1:1 to about 1:3 based on theweight of each of the first segments and the third segments.

In various aspects, the polymer can be a polyurethane elastomers,polyurea elastomers, polyamide elastomers (PEBA or polyether blockpolyamides), polyester elastomers, metallocene-catalyzed blockcopolymers of ethylene and α-olefins having 4 to about 8 carbon atoms,styrene block copolymers such as poly(styrene-butadiene-styrene),poly(styrene-ethylene-co-butylene-styrene), andpoly(styrene-isoprene-styrene), and combinations thereof.

Polyurethane may be selected from polyester-polyurethanes,polyether-polyurethanes, and polycarbonate-polyurethanes, including,without limitation, polyurethanes polymerized using as polymeric diolreactants polyethers and polyesters including polycaprolactonepolyesters. These polymeric diol-based polyurethanes are prepared byreaction of the polymeric diol (polyester diol, polyether diol,polycaprolactone diol, polytetrahydrofuran diol, or polycarbonate diol),one or more polyisocyanates, and, optionally, one or more chainextension compounds. Chain extension compounds, as the term is beingused, are compounds having two or more functional groups reactive withisocyanate groups, such as the diols, amino alcohols, and diamines.Preferably the polymeric diol-based polyurethane is substantially linear(i.e., substantially all of the reactants are difunctional).

Diisocyanates used in making the polyurethane may be aromatic oraliphatic. Useful diisocyanate compounds used to prepare thermoplasticpolyurethanes include, without limitation, isophorone diisocyanate(IPDI), methylene bis-4-cyclohexyl isocyanate (H₁₂MDI), cyclohexyldiisocyanate (CHDI), m-tetramethyl xylene diisocyanate (m-TMXDI),p-tetramethyl xylene diisocyanate (p-TMXDI), 4,4′-methylene diphenyldiisocyanate (MDI, also known as 4,4′-diphenylmethane diisocyanate),2,4- or 2,6-toluene diisocyanate (TDI), ethylene diisocyanate,1,2-diisocyanatopropane, 1,3-diisocyanatopropane, 1,6-diisocyanatohexane(hexamethylene diisocyanate or HDI), 1,4-butylene diisocyanate, lysinediisocyanate, meta-xylylenediioscyanate and para-xylylenediisocyanate,4-chloro-1,3-phenylene diisocyanate, 1,5-tetrahydro-naphthalenediisocyanate, 4,4′-dibenzyl diisocyanate, and xylylene diisocyanate(XDI), and combinations of these. Nonlimiting examples ofhigher-functionality polyisocyanates that may be used in limited amountsto produce branched thermoplastic polyurethanes (optionally along withmonofunctional alcohols or monofunctional isocyanates) include1,2,4-benzene triisocyanate, 1,3,6-hexamethylene triisocyanate,1,6,11-undecane triisocyanate, bicycloheptane triisocyanate,triphenylmethane-4,4′,4″-triisocyanate, isocyanurates of diisocyanates,biurets of diisocyanates, allophanates of diisocyanates, and the like.

Nonlimiting examples of suitable diols that may be used as extendersinclude ethylene glycol and lower oligomers of ethylene glycol includingdiethylene glycol, triethylene glycol and tetraethylene glycol;propylene glycol and lower oligomers of propylene glycol includingdipropylene glycol, tripropylene glycol and tetrapropylene glycol;cyclohexanedimethanol, 1,6-hexanediol, 2-ethyl-1,6-hexanediol,1,4-butanediol, 2,3-butanediol, 1,5-pentanediol, 1,3-propanediol,butylene glycol, neopentyl glycol, dihydroxyalkylated aromatic compoundssuch as the bis (2-hydroxyethyl) ethers of hydroquinone and resorcinol;p-xylene-α,α′-diol; the bis (2-hydroxyethyl) ether ofp-xylene-α,α′-diol; m-xylene-α,α′-diol and combinations of these.Thermoplastic polyurethanes may be made using small amounts of triols orhigher functionality polyols, such as trimethylolpropane orpentaerythritol, optionally along with monomeric alcohols such as C2-C8monools or monoisocyanates such as butyl isocyanate.

Useful active hydrogen-containing chain extension agents generallycontain at least two active hydrogen groups, for example, diols,dithiols, diamines, or compounds having a mixture of hydroxyl, thiol,and amine groups, such as alkanolamines, aminoalkyl mercaptans, andhydroxyalkyl mercaptans, among others. The molecular weight of the chainextenders preferably range from about 60 to about 400. Alcohols andamines are preferred. Examples of useful diols include those diolsalready mentioned. Suitable diamine extenders include, withoutlimitation, ethylene diamine, diethylene triamine, triethylenetetraamine, and combinations of these. Other typical chain extenders areamino alcohols such as ethanolamine, propanolamine, butanolamine, andcombinations of these. The dithiol and diamine reactants may also beincluded in preparing polyurethanes that are not elastomeric.

In addition to difunctional extenders, a small amount of a trifunctionalextender such as trimethylolpropane, 1,2,6-hexanetriol and glycerol, ormonofunctional active hydrogen compounds such as butanol or dimethylamine, may also be present. The amount of trifunctional extender ormonofunctional compound employed may be, for example, 5.0 equivalentpercent or less based on the total weight of the reaction product andactive hydrogen containing groups used.

The polyester diols used in forming a polyurethane are in generalprepared by the condensation polymerization of one or more polyacidcompounds and one or more polyol compounds. Preferably, the polyacidcompounds and polyol compounds are di-functional, i.e., diacid compoundsand diols are used to prepare substantially linear polyester diols,although minor amounts of mono-functional, tri-functional, and higherfunctionality materials (perhaps up to 5 mole percent) can be includedto provide a slightly branched, but uncrosslinked polyester polyolcomponent. Suitable dicarboxylic acids include, without limitation,glutaric acid, succinic acid, malonic acid, oxalic acid, phthalic acid,hexahydrophthalic acid, adipic acid, maleic acid, suberic acid, azelaicacid, dodecanedioic acid, their anhydrides and polymerizable esters(e.g., methyl esters) and acid halides (e.g., acid chlorides), andmixtures of these. Suitable polyols include those already mentioned,especially the diols. In preferred aspects, the carboxylic acidcomponent includes one or more of adipic acid, suberic acid, azelaicacid, phthalic acid, dodecanedioic acid, or maleic acid (or theanhydrides or polymerizable esters of these) and the diol componentincludes one or more of includes 1,4-butanediol, 1,6-hexanediol,2,3-butanediol, or diethylene glycol. Typical catalysts for theesterification polymerization are protonic acids, Lewis acids, titaniumalkoxides, and dialkyltin oxides.

A polymeric polyether or polycaprolactone diol reactant for preparingthermoplastic polyurethanes may be obtained by reacting a diolinitiator, e.g., 1,3-propanediol or ethylene or propylene glycol, with alactone or alkylene oxide chain-extension reagent. Lactones that can bering opened by an active hydrogen are well-known in the art. Examples ofsuitable lactones include, without limitation, ε-caprolactone,γ-caprolactone, β-butyrolactone, β-propriolactone, γ-butyrolactone,α-methyl-γ-butyrolactone, β-methyl-γ-butyrolactone, γ-valerolactone,δ-valerolactone, γ-decanolactone, δ-decanolactone, γ-nonanoic lactone,γ-octanoic lactone, and combinations of these. In one preferred aspect,the lactone is ε-caprolactone. Useful catalysts include those mentionedabove for polyester synthesis. Alternatively, the reaction can beinitiated by forming a sodium salt of the hydroxyl group on themolecules that will react with the lactone ring.

In other aspects, a diol initiator may be reacted with anoxirane-containing compound to produce a polyether diol to be used inthe polyurethane elastomer polymerization. Alkylene oxide polymersegments include, without limitation, the polymerization products ofethylene oxide, propylene oxide, 1,2-cyclohexene oxide, 1-butene oxide,2-butene oxide, 1-hexene oxide, tert-butylethylene oxide, phenylglycidyl ether, 1-decene oxide, isobutylene oxide, cyclopentene oxide,1-pentene oxide, and combinations of these. The oxirane-containingcompound is preferably selected from ethylene oxide, propylene oxide,butylene oxide, tetrahydrofuran, and combinations of these. The alkyleneoxide polymerization is typically base-catalyzed. The polymerization maybe carried out, for example, by charging the hydroxyl-functionalinitiator compound and a catalytic amount of caustic, such as potassiumhydroxide, sodium methoxide, or potassium tert-butoxide, and adding thealkylene oxide at a sufficient rate to keep the monomer available forreaction. Two or more different alkylene oxide monomers may be randomlycopolymerized by coincidental addition or polymerized in blocks bysequential addition. Homopolymers or copolymers of ethylene oxide orpropylene oxide are preferred. Tetrahydrofuran may be polymerized by acationic ring-opening reaction using such counterions as SbF₆ ⁻, AsF₆ ⁻,PF₆ ⁻, SbC₆ ⁻, BF₄ ⁻, CF₃SO₃ ⁻, FSO₃ ⁻, and ClO₄ ⁻. Initiation is byformation of a tertiary oxonium ion. The polytetrahydrofuran segment canbe prepared as a “living polymer” and terminated by reaction with thehydroxyl group of a diol such as any of those mentioned above.Polytetrahydrofuran is also known as polytetramethylene ether glycol(PTMEG).

Aliphatic polycarbonate diols that may be used in making a polyurethaneare prepared by the reaction of diols with dialkyl carbonates (such asdiethyl carbonate), diphenyl carbonate, or dioxolanones (such as cycliccarbonates having five- and six-member rings) in the presence ofcatalysts like alkali metal, tin catalysts, or titanium compounds.Useful diols include, without limitation, any of those alreadymentioned. Aromatic polycarbonates are usually prepared from reaction ofbisphenols, e.g., bisphenol A, with phosgene or diphenyl carbonate.

In various aspects, the polymeric diol preferably has a weight averagemolecular weight of at least about 500, more preferably at least about1000, and even more preferably at least about 1800 and a weight averagemolecular weight of up to about 10,000, but polymeric diols havingweight average molecular weights of up to about 5000, especially up toabout 4000, may also be preferred. The polymeric diol advantageously hasa weight average molecular weight in the range from about 500 to about10,000, preferably from about 1000 to about 5000, and more preferablyfrom about 1500 to about 4000. The weight average molecular weights canbe determined suitable methods such as those known in the art, e.g., bymeans of gel permeation chromatography, in accordance with ASTM D4001-13(ASTM D4001-13, Standard Test Method for Determination of Weight-AverageMolecular Weight of Polymers By Light Scattering, ASTM International,West Conshohocken, Pa., 2013), or per Schmitt, M. T., “Methods forPolymer Molecular Weight Measurement.” (see MNL17-2ND-EB Paint andCoating Testing Manual: 15th. Edition of the Gardner-Sward Handbook,edited by Joseph Koleske, (pp. 908-913). West Conshohocken, Pa.: ASTMInternational, 2012. doi:10.1520/MNL12254M).

The reaction of the polyisocyanate, polymeric diol, and diol or otherchain extension agent is typically carried out at an elevatedtemperature in the presence of a catalyst. Typical catalysts for thisreaction include organotin catalysts such as stannous octoate, dibutyltin dilaurate, dibutyl tin diacetate, dibutyl tin oxide, tertiaryamines, zinc salts, and manganese salts. Generally, the ratio ofpolymeric diol, such as polyester diol, to extender can be varied withina relatively wide range depending largely on the desired hardness of thefinal polyurethane elastomer. For example, the equivalent proportion ofpolyester diol to extender may be within the range of 1:0 to 1:12 and,more preferably, from 1:1 to 1:8. Preferably, the diisocyanate(s)employed are proportioned such that the overall ratio of equivalents ofisocyanate to equivalents of active hydrogen containing materials iswithin the range of 1:1 to 1:1.05, and more preferably, 1:1 to 1:1.02.The polymeric diol segments typically are from about 35 percent to about65 percent by weight of the polyurethane polymer, and preferably fromabout 35 percent to about 50 percent by weight of the polyurethanepolymer.

The selection of diisocyanate, extenders, polymeric diols, and theweight percent of the polymeric diols used takes into account thedesired density and stability of the desired foam. In general, a greatercontent of a polymeric polyol that has a Hildenbrand solubilityparameter closer to that of the supercritical fluid will permit higherabsorption of the supercritical fluid that results in a lower densityfoam. Also in general, shorter polymeric diols provide foams that shrinkless after they are first foamed. Use of higher number average molecularweight polymeric diols allow a higher degree of swelling, but amolecular weight that is too high may yield a less stable foam.

Suitable polyureas may be prepared by reaction of one or more polymericdiamines or polyols with one or more of the polyisocyanates alreadymentioned and one or more diamine extenders. Nonlimiting examples ofsuitable diamine extenders include ethylene diamine, 1,3-propylenediamine, 2-methyl-pentamethylene diamine, hexamethylene diamine, 2,2,4-and 2,4,4-trimethyl-1,6-hexane diamine, imino-bis(propylamine),imido-bis(propylamine), N-(3-aminopropyl)-N-methyl-1,3-propanediamine),1,4-bis(3-aminopropoxy)butane, diethyleneglycol-di(aminopropyl)ether),1-methyl-2,6-diamino-cyclohexane, 1,4-diamino-cyclohexane, 1,3- or1,4-bis(methylamino)-cyclohexane, isophorone diamine, 1,2- or1,4-bis(sec-butylamino)-cyclohexane, N,N′-diisopropyl-isophoronediamine, 4,4′-diamino-dicyclohexylmethane,3,3′-dimethyl-4,4′-diamino-dicyclohexylmethane,N,N′-dialkylamino-dicyclohexylmethane, and3,3′-diethyl-5,5′-dimethyl-4,4′-diamino-dicyclohexylmethane. Polymericdiamines include polyoxyethylene diamines, polyoxypropylene diamines,poly(oxyethylene-oxypropylene) diamines, and poly(tetramethylene ether)diamines. The amine- and hydroxyl-functional extenders already mentionedmay be used as well. Generally, as before, trifunctional reactants arelimited and may be used in conjunction with monofunctional reactants toprevent crosslinking.

Suitable polyamides may be obtained by: (1) polycondensation of (a) adicarboxylic acid, such as oxalic acid, adipic acid, sebacic acid,terephthalic acid, isophthalic acid, 1,4-cyclohexanedicarboxylic acid,or any of the other dicarboxylic acids already mentioned with (b) adiamine, such as ethylenediamine, tetramethylenediamine,pentamethylenediamine, hexamethylenediamine, or decamethylenediamine,1,4-cyclohexanediamine, m-xylylenediamine, or any of the other diaminesalready mentioned; (2) a ring-opening polymerization of a cyclic lactam,such as E-caprolactam or w-laurolactam; (3) polycondensation of anaminocarboxylic acid, such as 6-aminocaproic acid, 9-aminononanoic acid,11-aminoundecanoic acid, or 12-aminododecanoic acid; or (4)copolymerization of a cyclic lactam with a dicarboxylic acid and adiamine to prepare a carboxylic acid-functional polyamide block,followed by reaction with a polymeric ether diol (polyoxyalkyleneglycol) such as any of those already mentioned. Polymerization may becarried out, for example, at temperatures of from about 180 degreesCelsius to about 300 degrees Celsius Specific examples of suitablepolyamide blocks include NYLON 6, NYLON 66, NYLON 610, NYLON 11, NYLON12, copolymerized NYLON, NYLON MXD6, and NYLON 46.

The effects of the type and molecular weights of the soft segmentpolymeric polyols used in making thermoplastic polyurea elastomers andpolyamide elastomers are analogous to the same effects in makingthermoplastic polyurethane elastomers.

The polyesters can have blocks of monomer units with low chain lengththat form the crystalline regions and blocks of softening segments withmonomer units having relatively higher chain lengths. In some aspects,the polyesters can be thermoplastic polyester elastomers such as thosethat are commercially available under the tradename HYTREL from DuPont.

Metallocene-catalyzed block copolymers of ethylene and α-olefins having4 to about 8 carbon atoms are prepared by single-site metallocenecatalysis of ethylene with a softening comonomer such as hexane-1 oroctene-1, for example in a high pressure process in the presence of acatalyst system comprising a cyclopentadienyl-transition metal compoundand an alumoxane. Octene-1 is a preferred comonomer to use. Thesematerials are commercially available from ExxonMobil (Irving, Tex., USA)under the tradename EXACT and from the Dow Chemical Company (Midland,Mich., USA) under the tradename ENGAGE.

Styrene block copolymer such as poly(styrene-butadiene-styrene),poly(styrene-ethylene-co-butylene-styrene), andpoly(styrene-isoprene-styrene) may be prepared may anionicpolymerization in which the polymer segments are produced sequentially,first by reaction of an alkyl-lithium initiator with styrene, thencontinuing polymerization by adding the alkene monomer, then completingpolymerization by again adding styrene. S-EB-S and S-EP-S blockcopolymers are produced by hydrogenation of S-B-S and S-I-S blockcopolymers, respectively.

Foamed Preform.

In various aspects, a foamed preform comprising a disclosed polymer canbe formed by molding the polymer, e.g., compression molding or injectionmolding, to a desired shape as known to the skilled artisan. The preformcan be foamed during or after the molding process. In various aspects,the foam structure of the foamed preform is a closed cell foamstructure.

In a further aspect, foaming a foamed preform after the molding processcan comprise infusion of a molded preform, preferably to saturation,with a supercritical fluid, which in some aspects is a supercriticalcarbon dioxide. Nonlimiting examples of suitable compounds that can beused as the supercritical fluid include carbon dioxide (criticaltemperature 31.1 degrees Celsius, critical pressure 7.38 MPa), nitrousoxide (critical temperature 36.5 degrees Celsius, critical pressure 7.24MPa), ethane (critical temperature 32.3 degrees Celsius, criticalpressure 4.88 MPa), ethylene (critical temperature 9.3 degrees Celsius,critical pressure 5.12 MPa), nitrogen (critical temperature −147 degreesCelsius, critical pressure 3.39 MPa), and oxygen (critical temperature−118.6 degrees Celsius, critical pressure 5.08 MPa).

Carbon dioxide is often used as a supercritical fluid in differentprocesses. The supercritical carbon dioxide fluid can be made morecompatible with the polar thermoplastic elastomers (particularlythermoplastic polyurethane, polyurea, and polyamide elastomers) bymixing it with a polar fluid such as methanol, ethanol, propanol, orisopropanol. The polar fluid that is used should have a Hildebrandsolubility parameter equal to or greater than 9 MPa^(−1/2). Increasingthe weight fraction of the polar fluid increases the amount of carbondioxide uptake, but the polar fluid is also taken up, and at some pointthere is a shift from a maximum amount of uptake of the supercriticalcarbon dioxide to an increasing amount of the non-foaming agent polarfluid being taken up by the thermoplastic elastomer article. In certainaspects, from about 0.1 mole percent to about 7 mole percent of thepolar fluid is included in the supercritical fluid, based on totalfluid, especially when used to infuse a polyurethane elastomer, polyureaelastomer, or a polyamide elastomer.

Supercritical fluids may be used in combination. In some cases,supercritical nitrogen may be used as a nucleating agent in a smallweight percentage along with supercritical carbon dioxide or anothersupercritical fluid that acts as the blowing agent. Nano-sized particlessuch as nano clays, carbon black, crystalline, immiscible polymers, andinorganic crystals such as salts can be included as nucleating agents.

The preform can be placed in a vessel that can withstand high pressure.The vessel is closed and a foaming agent, e.g., carbon dioxide,nitrogen, mixtures of carbon dioxide and nitrogen, or other type offoaming agent is introduced. The vessel temperature and pressure aremaintained above the critical temperature and pressure of the foamingagent. Once the preform is saturated with the foaming agent, the vesselis rapidly depressurized (the depressurizing process can last up to aminute or so). The preform is then removed from the vessel and heated toproduce the foamed prefoam. When a co-solvent is used, it can beintroduced along with the foaming agent, e.g., carbon dioxide, nitrogen,mixtures of carbon dioxide and nitrogen, or other type of foaming agent,to the vessel with the article before the vessel is closed.

The preform can be soaked in the supercritical fluid underconditions—temperature and pressure—and for a time to allow it to takeup a desired amount of the supercritical fluid.

In various aspects, the preform can be soaked under conditions thatresult in it becoming saturated with the supercritical fluid. Thepreform is then removed from the chamber and immediately either heatedto a temperature in a medium with suitable thermal characteristics forfoaming to occur or is exposed to microwaves or infrared radiation in atunnel or oven to cause the foaming to occur. In microwave heating, thematerial is exposed to an electromagnetic wave that causes the moleculesin the material to oscillate, thereby generating heat. The system can bedesigned to work in batch or continuous process. In a batch process, thepreform saturated with the supercritical fluid is placed in a microwaveoven or a device equipped with an IR lamp or IR lamps. Preferably thepreform is rotated or agitated, when their size is small enough, toensure fast and uniform heating. When foaming is completed, the articlesare removed from the system. The heating can also be done in thecontinuous process. The preform can be placed on a planar surface suchas a belt that moves them through a tunnel or through a pipe. The systemis designed so that the heating elements (IR lamp or microwavegenerator) can apply power to achieve rapid uniform heating. The time ofheating is controlled by the speed by which the articles move throughthe tunnel or pipe.

Water is one suitable medium in which foaming readily occurs at anappropriate temperature because water has a high heat capacity and heattransfer rate. In certain preferred aspects, the thermoplastic elastomerarticle infused or saturated with supercritical fluid is submerged inwater that is at a temperature at least about 80 degrees C. higher and,preferably, at least about 100 degrees C. higher than the elastomers(soft segment) glass transition temperature but less than the elastomers(hard segment) melting temperature. Other suitable mediums are steam orpressurized hot air.

Time, temperature, and pressure in the step of solvating the preformarticle with the supercritical fluid and the depressurization rate,temperature, and medium in the foaming step all affect the degree offoaming achieved. In general, a thicker article must be kept in thesupercritical fluid for a longer time to become saturated with thesupercritical fluid.

The preform may be annealed at an elevated temperature after the foamingprocess. While not wishing to be bound by theory, it is believed thatannealing the article may allow phase segregation of the elastomers thatare placed under strain, e.g. the mold, and stress, a partial pressureexternal to moderate internal pressure equilibration just after rapidfoaming. Cooling under balanced forces allow the increased modulus tomaintain shape once at room temperature and atmospheric pressure.

The preform may be annealed at a temperature from above ambient to justbelow the T_(m) of the thermoplastic elastomer (which may be determineby the usual appropriate thermal methods, of which differential scanningcalorimetry (DSC) may be mentioned) for a time sufficient to stabilizethe foam.

Articles Comprising the Disclosed Compression Molded Foam Articles.

The present disclosure also pertains to articles comprising a disclosedmolded foam article. For example, an article of the present disclosecomprising a disclosed molded foam article can be an article offootwear, a component of an article of footwear, an article of apparel,a component of an article of apparel, an article of sporting equipment,or a component of an article of sporting equipment. That is, thedisclosed molded foam articles can be utilized in the manufacture of avariety of articles or components, e.g., a component used in an articleof footwear or a cushioning element, which can be utilized in themanufacture of an article.

In some aspects, the disclosed article can be an article of footwear,including, but not limited to, a shoe, a boot, or a sandal. In aparticular aspect, the disclosed article is a shoe. A shoe can be anathletic shoe, including, but not limited to, a baseball shoe, abasketball shoe, a soccer shoe, a football shoe, a running shoe, across-trainer shoe, a track shoe, or a golf shoe.

In a further aspect, the disclosed article is a component of an articleof footwear. In particular aspects, the component of an article offootwear can be a midsole, an outsole, an insole, or an insertcomprising a disclosed molded foam article. Additional components of anarticle of footwear comprising a disclosed molded foam article caninclude a tongue padding, a collar padding, and a combination thereof.As described above and detailed more completely below, the articlescomprising the disclosed molded foam articles can exhibit a uniquebalance of beneficial physical properties such as high energy return orlow stiffness in an anisotropic manner. For example, the disclosedmolded foam articles can exhibit differences these properties alongdifferent axes of the molded foam article.

In some aspects, the component of an article of footwear is a cushioningelement. In such contexts, the cushioning element is configured to havea majority of force applied in a first direction during use; and whereinthe first axis is parallel to the first direction. The cushioningelement in an article of footwear can be a midsole or a sockliner.

In various aspects, the disclosed molded foam articles and the moldedfoam article made using the disclosed methods can produce molded foamarticles having physical properties which make these articlesparticularly advantageous for use as components in articles of footwearand athletic equipment. For example, the physical properties of thesemolded foam articles make them particularly useful for use as cushioningelements, such as midsoles. Moreover, the disclosed methods can be usedto prepare molded foam articles comprising anisotropic cell structurethat can be used generally in an article or application that can benefitfrom use of a foam material where directionality of foam properties isdesirable, such as seat cushions, impact protection devices. Inparticular, the disclosed methods can be used to prepare molded foamarticles comprising anisotropic cell structure that provide a foam thatis characterized by a foam feel softer at least along certain axes.

As described above, the disclosed molded foam articles and the moldedfoam articles made using the disclosed methods described herein canexhibit sub-regions having different properties such as, but not limitedto, efficiency. The sub-regions can be discrete regions having aproperty distributed more or less uniformly within the sub-region. Inother aspects, the article manufactured by the disclosed methods may becharacterized by a gradient distribution of the property along aparticular axis, e.g., the z-axis of the article or component comprisinga disclosed molded foam article.

In various aspects, the article is an article of sporting equipment or acomponent of an article of sporting equipment. In a particular aspect,the article is a component of an article of sporting equipment, e.g., acushioning element. The cushioning element that is a component of anarticle of sporting equipment can be a hat, a component of a bag, acomponent of a ball, and a component of protective equipment.

The article of the present disclosure can be an article of apparel or acomponent of an article of apparel. In some aspects, the component of anarticle of apparel is a cushioning element such as a collar, a hem, alapel, or other apparel elements that can benefit from directionality offoam properties for enhanced appearance, function, or both.

In some aspects, the article comprising a disclosed molded foam articlecan be a cushioning element in shinguards, shoulder pads, chestprotectors, masks, helmets or other headgear, knee protectors, and otherprotective equipment; a component placed in an article of clothingbetween textile layers; or may be used for other known paddingapplications for protection or comfort, especially those for whichweight of the padding is a concern. In some aspects, the article is acushioning element used in a sports helmet, a backpack, apparel, sportsuniform padding, or combat gear.

Efficiency Test Method.

A. Efficiency Test Method: Testing of a Plaque Specimen.

Testing of sample plaque specimens is performed on an InstronElectroPuls E10000 dynamic testing system (Illinois Tool Works Inc.,Norwood, Mass., USA), equipped with a cylindrical tupp where thecontacting diameter is 44.86 millimeters. 500 sinusoidal compressioncycles are performed with a frequency of 2 Hertz and are forcecontrolled to 300 N. Compressive stiffness, efficiency, and energyreturn are measured from these tests. Compressive stiffness for eachcycle corresponds to the peak stress normalized by the strain at maxload where stress and strain are defined as force/area anddeflection/thickness, respectively. Efficiency is the integral of theunloading load deflection curve normalized by the integral of loadingload deflection curve. Energy return is the integral of the unloadingload deflection curve. The metrics reported for an individual plaquespecimen are the average of the 100^(th), 200^(th), 300^(th), and400^(th) cycles. A representative graph of data for a plaque specimen isshown in FIG. 8 . In FIG. 8 , the relevant metrics are indicated on thegraph where where “stiff”=compressive stiffness [kilopascals] and“eff”=efficiency, and “energy out”=energy return.

B. Efficiency Test Method: Testing of a Midsole.

Efficiency Testing can also be used to test a foam preform or a moldedfoam article such as a midsole. Compression testing is performed on anInstron ElectroPuls E10000 dynamic testing system (Illinois Tool WorksInc., Norwood, Mass., USA) with a last-shaped tupp sized to correspondto the size of the midsole being tested. Testing of a midsole involvescompressing the midsole in the heel and forefoot using a last pressurematched to a performance runner's running stride. Experiments are run inforce control up to a maximum load of 600 N using 100 compressive cyclesperformed at approximately 1.1 hertz using a waveform for an athletefootstrike force profile, e.g. an athlete such as a long-distancerunner. The waveform employs a half period of sine wave to apply animpulse. After the impulse is complete, the midsole is left unloaded forthe remainder of the cycle. The load-rest cycle is repeated for thedesired number of cycles. Waveform details: pulse amplitude=600 N; pulsewidth=0.2 seconds; pulse shape=half period of sine wave; and rest=0.8seconds, repeat.

Compressive stiffness, efficiency, and energy return are measured fromthese tests. Compressive stiffness for each cycle corresponds to thepeak load normalized by the deflection at that max load. For molded foamarticles such as midsoles (i.e., any non-plaque geometry) stiffness isreported in N/mm. Efficiency is the integral of the unloading loaddeflection curve normalized by the integral of loading load deflectioncurve. Energy return is the integral of the unloading load deflectioncurve. The metrics reported for an individual midsole are the average ofthe 60^(th), 70^(th), 80^(th), and 90^(th) cycles. A representativegraph of data for a midsole is shown in FIG. 7 . In FIG. 8 , therelevant metrics are indicated on the graph where “stiff”=compressivestiffness [N/mm] “energy out”=energy return [mJ], and “eff”=efficiency.

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this disclosure belongs. It will be further understoodthat terms, such as those defined in commonly used dictionaries, shouldbe interpreted as having a meaning that is consistent with their meaningin the context of the specification and relevant art and should not beinterpreted in an idealized or overly formal sense unless expresslydefined herein.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a polymer,” “amold,” or “a foamed preform,” including, but not limited to, two or moresuch polymers, molds, or preform, and the like.

Reference to “a” chemical compound refers one or more molecules of thechemical compound, rather than being limited to a single molecule of thechemical compound. Furthermore, the one or more molecules may or may notbe identical, so long as they fall under the category of the chemicalcompound. Thus, for example, “a” polyamide is interpreted to include oneor more polymer molecules of the polyamide, where the polymer moleculesmay or may not be identical (e.g., different molecular weights and/orisomers).

It should be noted that ratios, concentrations, amounts, and othernumerical data can be expressed herein in a range format. Where thestated range includes one or both of the limits, ranges excluding eitheror both of those included limits are also included in the disclosure,e.g. the phrase “x to y” includes the range from ‘x’ to ‘y’ as well asthe range greater than ‘x’ and less than ‘y’. The range can also beexpressed as an upper limit, e.g. ‘about x, y, z, or less’ and should beinterpreted to include the specific ranges of ‘about x’, ‘about y’, and‘about z’ as well as the ranges of ‘less than x’, less than y′, and‘less than z’. Likewise, the phrase ‘about x, y, z, or greater’ shouldbe interpreted to include the specific ranges of ‘about x’, ‘about y’,and ‘about z’ as well as the ranges of ‘greater than x’, greater thany′, and ‘greater than z’. In addition, the phrase “about ‘x’ to ‘y’”,where ‘x’ and ‘y’ are numerical values, includes “about ‘x’ to about‘y’”. It is to be understood that such a range format is used forconvenience and brevity, and thus, should be interpreted in a flexiblemanner to include not only the numerical values explicitly recited asthe limits of the range, but also to include all the individualnumerical values or sub-ranges encompassed within that range as if eachnumerical value and sub-range is explicitly recited. To illustrate, anumerical range of “about 0.1 percent to 5 percent” should beinterpreted to include not only the explicitly recited values of about0.1 percent to about 5 percent, but also include individual values(e.g., 1 percent, 2 percent, 3 percent, and 4 percent) and thesub-ranges (e.g., 0.5 percent, 1.1 percent, 2.4 percent, 3.2 percent,and 4.4 percent) within the indicated range.

As used herein, the terms “about,” “approximate,” “at or about,” and“substantially” mean that the amount or value in question can be theexact value or a value that provides equivalent results or effects asrecited in the claims or taught herein. That is, it is understood thatamounts, sizes, formulations, parameters, and other quantities andcharacteristics are not and need not be exact, but may be approximateand/or larger or smaller, as desired, reflecting tolerances, conversionfactors, rounding off, measurement error and the like, and other factorsknown to those of skill in the art such that equivalent results oreffects are obtained. In some circumstances, the value that providesequivalent results or effects cannot be reasonably determined. In suchcases, it is generally understood, as used herein, that “about” and “ator about” mean the nominal value indicated plus or minus 10 percentvariation unless otherwise indicated or inferred. In general, an amount,size, formulation, parameter or other quantity or characteristic is“about,” “approximate,” or “at or about” whether or not expressly statedto be such. It is understood that where “about,” “approximate,” or “ator about” is used before a quantitative value, the parameter alsoincludes the specific quantitative value itself, unless specificallystated otherwise.

As used herein, “anisotropic” means having different properties ordegrees of properties in different directions (or axes) or alongdifferent planes. An anisotropic property can be a mechanical propertysuch as energy return, stiffness value, or elasticity. In this context,“such that energy return is an anisotropic property” would mean that thevalue of the energy return is different along one axis compared to aanother axis. In some instances, the axes are perpendicular to oneanother and correspond to one of a x-, y- and z-axis such that the x-and y-axis define a plane defining a major plane such as across-sectional plan lengthwise through a midsole. For example, theenergy return of a foam in length (y direction) may be different than inthickness (z direction) and/or in width (x direction).

As used herein, “substantially anisotropic property” or “having asubstantially anisotropic property” means that at least one mechanicalproperty, e.g., energy return (“having a substantially anisotropicenergy return”), in an area, region, or volume of the foam having asubstantially anisotropic property is at least about 5 percent differentin a first axis compared to a second or a third axis perpendicular tothe first axis, and such that the second and third axis areperpendicular to one another.

As used herein, “anisotropic cell shape” means that the cells in aclosed cell foam have a shape which has different dimensions indifferent spatial directions, such as directions along the x-, y- andz-axis of the foam closed cell. The largest dimension of the cell can bereferred to as “a direction”. Anisotropic foam cell shapes can be, butare not limited to, ellipsoid, tri-axial ellipsoid, oblate spheroid,prolate spheroid, or mixtures thereof.

As used herein, “substantially anisotropic cell shape” or “having asubstantially anisotropic cell shape” means that in a population ofcells in a foam, at least about 60 percent of the cells have ananisotropic cell shape within an area, region or volume of the foamhaving a substantially anisotropic cell shape.

As used herein, “isotropic” means having similar properties or degreesof properties in different directions (or axes) or along differentplanes. An isotropic property can be a mechanical property such asenergy return, stiffness value, or elasticity. In this context, “suchthat energy return is an isotropic property” would mean that the valueof the energy return is similar or substantially the same along one axiscompared to another axis.

As used herein, “substantially isotropic property” or “having asubstantially isotropic property” means that at least one mechanicalproperty, e.g., energy return (“having a substantially isotropic energyreturn”), in an area, region, or volume of the foam having asubstantially isotropic property is less than 5 percent different in afirst axis compared to a second or a third axis perpendicular to thefirst axis, and such that the second and third axis are perpendicular toone another.

As used herein, “isotropic cell shape” means that the cells in a closedcell foam have a shape which has similar or the same dimensions indifferent spatial directions, such as directions along the x-, y- andz-axis of the foam closed cell.

As used herein, “substantially isotropic cell shape” or “having asubstantially isotropic cell shape” means that in a population of cellsin a foam, at least about 60 percent of the cells have an isotropic cellshape within an area, region or volume of the foam having asubstantially isotropic cell shape.

As used herein, the terms “optional” or “optionally” means that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

As used herein, the term “units” can be used to refer to individual(co)monomer units such that, for example, styrenic repeat units refersto individual styrene (co)monomer units in the polymer. In addition, theterm “units” can be used to refer to polymeric block units such that,for example, “styrene repeating units” can also refer to polystyreneblocks; “units of polyethylene” refers to block units of polyethylene;“units of polypropylene” refers to block units of polypropylene; “unitsof polybutylene” refers to block units of polybutylene, and so on. Suchuse will be clear from the context.

The term “copolymer” refers to a polymer having two or more monomerspecies, and includes terpolymers (i.e., copolymers having three monomerspecies).

Unless otherwise specified, temperatures referred to herein are based onatmospheric pressure (i.e. one atmosphere).

Disclosed are the components to be used to prepare the compositions ofthe invention as well as the compositions themselves to be used withinthe methods disclosed herein. These and other materials are disclosedherein, and it is understood that when combinations, subsets,interactions, groups, etc. of these materials are disclosed that whilespecific reference of each various individual and collectivecombinations and permutation of these compounds cannot be explicitlydisclosed, each is specifically contemplated and described herein. Forexample, if a particular compound is disclosed and discussed and anumber of modifications that can be made to a number of moleculesincluding the compounds are discussed, specifically contemplated is eachand every combination and permutation of the compound and themodifications that are possible unless specifically indicated to thecontrary. Thus, if a class of molecules A, B, and C are disclosed aswell as a class of molecules D, E, and F and an example of a combinationmolecule, A-D is disclosed, then even if each is not individuallyrecited each is individually and collectively contemplated meaningcombinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considereddisclosed. Likewise, any subset or combination of these is alsodisclosed. Thus, for example, the sub-group of A-E, B-F, and C-E wouldbe considered disclosed. This concept applies to all aspects of thisapplication including, but not limited to, steps in methods of makingand using the compositions of the invention. Thus, if there are avariety of additional steps that can be performed it is understood thateach of these additional steps can be performed with any specific aspector combination of aspects of the methods of the invention.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition or article,denotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a compound containing 2 parts byweight of component X and 5 parts by weight component Y, X and Y arepresent at a weight ratio of 2:5, and are present in such ratioregardless of whether additional components are contained in thecompound.

As used herein the terms “weight percent,” “wt percent,” and “wt.percent,” which can be used interchangeably, indicate the percent byweight of a given component based on the total weight of thecomposition, unless otherwise specified. That is, unless otherwisespecified, all wt percent values are based on the total weight of thecomposition. It should be understood that the sum of wt percent valuesfor all components in a disclosed composition or formulation are equalto 100.

Compounds are described using standard nomenclature. For example, anyposition not substituted by any indicated group is understood to haveits valence filled by a bond as indicated, or a hydrogen atom. A dash(“-”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, —CHO is attachedthrough carbon of the carbonyl group. Unless defined otherwise,technical and scientific terms used herein have the same meaning as iscommonly understood by one of skill in the art to which this inventionbelongs.

The term “alkyl group” as used herein is a branched or unbranchedsaturated hydrocarbon group of 1 to 24 carbon atoms, such as methyl,ethyl, n propyl, isopropyl, n butyl, isobutyl, t butyl, pentyl, hexyl,heptyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and thelike. A “lower alkyl” group is an alkyl group containing from one to sixcarbon atoms.

The term “aryl group” as used herein is any carbon-based aromatic groupincluding, but not limited to, benzene, naphthalene, etc. The term“aromatic” also includes “heteroaryl group,” which is defined as anaromatic group that has at least one heteroatom incorporated within thering of the aromatic group. Examples of heteroatoms include, but are notlimited to, nitrogen, oxygen, sulfur, and phosphorus. The aryl group canbe substituted or unsubstituted. The aryl group can be substituted withone or more groups including, but not limited to, alkyl, alkynyl,alkenyl, aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy,carboxylic acid, or alkoxy.

Aspects

The following listing of exemplary aspects supports and is supported bythe disclosure provided herein.

Aspect 1. A foam article comprising: an elastomeric material having aclosed cell foam structure comprising a plurality of cells having ananisotropic cell shape; wherein the foam article comprises a first axis,a second axis and a third axis; wherein the first axis is perpendicularto the second axis and the third axis; wherein the second axis and thethird axis are each perpendicular to each other; wherein the second andthe third axis define a plane parallel to a major surface of the foamarticle; and wherein a physical property determined along the first axisis different from the physical property determined along the secondaxis, the third axis, or both the second and third axis.

Aspect 2. The foam article of Aspect 1, wherein the foam article is acompression molded foam article.

Aspect 3. The foam article of Aspect 2, wherein the first axis isparallel to a direction in which compression is applied during acompression molding process.

Aspect 4. The foam article of any one of Aspect 1-Aspect 3, wherein thephysical property determined along the first axis differs from thephysical property determined along the second axis, the third axis, orboth the second and third axes by at least 5 percent, or at least 10percent, or at least 20 percent.

Aspect 5. The foam article of any one of Aspect 1-Aspect 4, wherein theplurality of cells have an average aspect ratio that is an average ratioof the second axis to the first axis; wherein a major axis is parallelto the second axis; wherein a minor axis is parallel to the first axis;and wherein the average aspect ratio is from about 1.5 to about 15; oris from about 2 to about 15; or is from about 2.5 to about 15; or isfrom about 5 to about 15; or is from about 7.5 to about 15; or is fromabout 10 to about 15; or is from about 2 to about 10; or is from about2.5 to about 10; or is from about 5 to about 10; or is from about 7.5 toabout 10.

Aspect 6. The foam article of any one of Aspect 1-Aspect 5, wherein theplurality of cells are aligned in an orientation along the second axiswithin a range of a solid angle of about plus or minus 20 degrees; orabout plus or minus 15 degrees; or of about plus or minus 10 degrees; orof about plus or minus 5 degrees.

Aspect 7. The foam article of any one of Aspect 1-Aspect 6, wherein theplurality of cells having an anisotropic cell shape are dispersedthroughout the foam article.

Aspect 8. The foam article of Aspect 7, wherein dispersed throughout theclosed cell foam structure is distributed substantially throughout anentire height of the foam article as determined along a dimensionparallel to the first axis.

Aspect 9. The foam article of Aspect 7, wherein the plurality of cellshaving the anisotropic cell shape are present in a region of the foamarticle that does not include an external skin of the foam article, andthe region occupies at least 1 cubic centimeter, or at least 3 cubiccentimeters, or at least 5 cubic centimeters of a total volume of thefoam article.

Aspect 10. The foam article of Aspect 7, wherein dispersed throughoutthe closed cell foam structure is distributed substantially uniformlythroughout a height of the foam article.

Aspect 11. The foam article of any one of Aspect 1-Aspect 10, whereinthe foam article has a foam article volume; and wherein the plurality ofcells having an anisotropic cell shape comprising a percent of the foamarticle volume that is from about 10 percent to about 100 percent; orabout 20 percent to about 100 percent; or about 30 percent to about 100percent; or about 40 percent to about 100 percent; or about 50 percentto about 100 percent; or about 60 percent to about 100 percent; or about70 percent to about 100 percent; or about 80 percent to about 100percent; or about 90 percent to about 100 percent; or 10 percent toabout 90 percent; or about 20 percent to about 90 percent; or about 30percent to about 90 percent; or about 40 percent to about 90 percent; orabout 50 percent to about 90 percent; or about 60 percent to about 90percent; or 70 percent to about 90 percent; or about 80 percent to about90 percent.

Aspect 12. The foam article of any one of Aspect 1-Aspect 10, whereinthe foam article has a foam article weight; and wherein the plurality ofcells having an anisotropic cell shape comprising a percent of the foamarticle weight that is from about 10 percent to about 100 percent; orabout 20 percent to about 100 percent; or about 30 percent to about 100percent; or about 40 percent to about 100 percent; or about 50 percentto about 100 percent; or about 60 percent to about 100 percent; or about70 percent to about 100 percent; or about 80 percent to about 100percent; or about 90 percent to about 100 percent; or about 10 percentto about 90 percent; or about 20 percent to about 90 percent; or about30 percent to about 90 percent; or about 40 percent to about 90 percent;or about 50 percent to about 90 percent; or about 60 percent to about 90percent; or about 70 percent to about 90 percent; or about 80 percent toabout 90 percent.

Aspect 13. The foam article of any one of Aspect 1-Aspect 10, whereinthe foam article has a foam article cell number representing a totalnumber of closed cells contained within the foam article; and whereinthe plurality of cells having an anisotropic cell shape comprise apercent of the foam article cell number that is from about 10 percent toabout 100 percent; or about 30 percent to about 100 percent; about 40percent to about 100 percent; or about 50 percent to about 100 percent;or about 60 percent to about 100 percent; or about 70 percent to about100 percent; or about 80 percent to about 100 percent; or about 90percent to about 100 percent; or about 10 percent to about 90 percent;or about 20 percent to about 90 percent; or about 30 percent to about 90percent; or about 40 percent to about 90 percent; or about 50 percent toabout 90 percent; or about 60 percent to about 90 percent; or about 70percent to about 90 percent; or about 80 percent to about 90 percent.

Aspect 14. The foam article of any one of Aspect 1-Aspect 13, whereinthe foam article has a foam article average height along an axisparallel to the first axis; wherein the plurality of cells having ananisotropic shape are distributed along a percent of the foam articleaverage height that is at least about 10 percent; or at least about 20percent; or at least about 30 percent; or at least about 40 percent; orat least about 50 percent; or at least about 60 percent; or at leastabout 70 percent; or at least about 80 percent; or at least about 90percent.

Aspect 15. The foam article of any one of Aspect 1-Aspect 14, whereinthe anisotropic cell shape is ellipsoid.

Aspect 16. The foam article of Aspect 15, wherein the anisotropic cellshape is tri-axial ellipsoid, oblate spheroid, prolate spheroid, ormixtures thereof.

Aspect 17. The foam article of any one of Aspect 1-Aspect 16, whereinthe physical property is at least one physical property.

Aspect 18. The foam article of any one of Aspect 1-Aspect 17, whereinthe physical property is efficiency.

Aspect 19. The foam article of Aspect 18, wherein the efficiency in thefirst axis of the foam article, when determined in accordance withEfficiency Test Method, is greater than or equal to about 5 percent; orabout 15 percent; or about 20 percent; or about 25 percent; or about 30percent; or about 35 percent; or about 40 percent; or about 45 percent;or about 50 percent; or about 55 percent; or about 60 percent; or about65 percent; or about 65 percent; or about 70 percent; or about 75percent; or about 80 percent; or about 82 percent; or about 84 percent;or about 86 percent; or about 88 percent; or about 89 percent; or about90 percent; or about 91 percent; or about 92 percent; or about 93percent; or about 94 percent; or about 95 percent; or about 96 percent;or about 97 percent; or about 98 percent; or about 99 percent; or about100 percent; or about 150 percent; or about 200 percent; or about 250percent; or about 300 percent; or about 350 percent; or about 400percent; or about 450 percent; or about 500 percent; or about 600percent; or about 700 percent; or about 800 percent; or about 900percent; or about 1000 percent; or about 1500 percent; or about 2000percent; or about 2100 percent; or about 2200 percent.

Aspect 20. The foam article of Aspect 18, wherein the efficiency in thefirst axis of the foam article, when determined in accordance withEfficiency Test Method, is from about 60 percent to about 99 percent; orabout 65 percent to about 99 percent; or about 70 percent to about 99percent; or about 75 percent to about 99 percent; or about 80 percent toabout 99 percent; or about 82 percent to about 99 percent; or about 84percent to about 99 percent; or about 86 percent to about 99 percent; orabout 88 percent to about 99 percent.

Aspect 21. The foam article of any one of Aspect 19 or Aspect 20,wherein the efficiency of the foam article determined along the secondaxis, the third axis, or both the second and third axes is less than orequal to an efficiency determined along the first axis of the foamarticle.

Aspect 22. The foam article of Aspect 21, wherein the efficiency of thefoam article determined along the first axis is at least 5 percentgreater, or at least 10 percent greater, or at least 20 percent greaterthan the efficiency of the foam article determined along the secondaxis, the third axis, or both the second and third axes of the foamarticle.

Aspect 23. The foam article of Aspect 18, wherein a reference foamarticle is compression molded and comprises essentially the samepolymeric material and has substantially the same density as the foamarticle; wherein the reference foam article has a closed cell structurethat is substantially isotropic; and wherein the foam article exhibitsan efficiency determined along the first axis of the foam articlegreater than the reference foam article, when determined in accordancewith Efficiency Test Method, by about 1.0 percent to about 50 percent;or about 2.5 percent to about 50 percent; or about 5 percent to about 50percent; or about 7.5 percent to about 50 percent; or about 10 percentto about 50 percent; or about 12.5 percent to about 50 percent; or about15 percent to about 50 percent; or about 17.5 percent to about 50percent; or about 20 percent to about 50 percent greater; or about 2.5percent to about 25 percent; or about 5 percent to about 25 percent; orabout 7.5 percent to about 25 percent; or about 10 percent to about 25percent; or about 12.5 percent to about 25 percent; or about 15 percentto about 25 percent; or about 17.5 percent to about 25 percent; or about20 percent to about 25 percent; or about 2.5 percent to about 22.5percent; or about 2.5 percent to about 20 percent; or about 2.5 percentto about 17.5 percent; or about 2.5 percent to about 15 percent; orabout 2.5 percent to about 10 percent; or about 2.5 percent to about 7.5percent; or about 1 percent to about 5 percent; or about 1 percent toabout 7.5 percent; or about 1 percent to about 10 percent.

Aspect 24. The foam article of Aspect 23, wherein there is substantiallyno change in an efficiency determined along the second axis, the thirdaxis, or both the second and third axes of the foam article compared toan efficiency determined along the second axis, third axis, or both thesecond and third axes of the reference foam article.

Aspect 25. The foam article of Aspect 23 or Aspect 24, wherein there isa decrease in an efficiency determined along the second axis, the thirdaxis, or both the second and third axes of the foam article compared toan efficiency determined along the second axis, third axis, or both thesecond and third axes of the reference foam article.

Aspect 26. The foam article of any one of Aspect 23-Aspect 25, whereinan efficiency of the foam article determined along the second axis, thethird axis, or both the second and third axes is less than or equal toan efficiency determined along the first axis of the foam article.

Aspect 27. The foam article of article of Aspect 26, wherein theefficiency of the foam article determined along the first axis is atleast about 5 percent greater, or at least about 10 percent greater, orat least about 20 percent greater than the efficiency of the foamarticle determined along the second axis, the third axis, or both thesecond and third axes of the foam article.

Aspect 28. The foam article of any one of Aspect 1-Aspect 17, whereinthe physical property is energy return.

Aspect 29. The foam article of Aspect 28, wherein a reference foamarticle is compression molded and comprises essentially the samepolymeric material and has substantially the same density as the foamarticle; wherein the reference foam article has a closed cell structurethat is substantially isotropic; and wherein the foam article exhibitsan energy return determined along the first axis of the foam articlegreater than the reference foam article, when determined in accordancewith Efficiency Test Method, by from about 1.0 percent to about 70percent; or about 2.5 percent to about 60 percent; or about 5 percent toabout 50 percent; or about 7.5 percent to about 50 percent; or about 10percent to about 50 percent; or about 12.5 percent to about 50 percent;or about 15 percent to about 50 percent; or about 17.5 percent to about50 percent; or about 20 percent to about 50 percent; or about 2.5percent to about 40 percent; or about 2.5 percent to about 30 percent;or about 2.5 percent to about 25 percent; or about 2.5 percent to about20 percent; or about 2.5 percent to about 17.5 percent; or about 2.5percent to about 15 percent; or about 1 percent to about 40 percent; orabout 1 percent to about 30 percent; or about 1 percent to about 20percent.

Aspect 30. The foam article of article of Aspect 29, wherein an energyreturn of the foam article determined along the second axis, the thirdaxis, or both the second and third axes is less than or equal to anenergy return determined along the first axis of the foam article.

Aspect 31. The foam article of article of Aspect 30, wherein the energyreturn of the foam article determined along the first axis is at leastabout 5 percent greater, or at least about 10 percent greater, or atleast about 20 percent greater than the energy return of the foamarticle determined along the second axis, the third axis, or both thesecond and third axes of the foam article.

Aspect 32. The foam article of Aspect 28, wherein a reference foamarticle is compression molded and comprises essentially the samepolymeric material and has substantially the same density as the foamarticle; wherein the reference foam article has a closed cell structurethat is substantially isotropic; and wherein the foam article exhibitsan energy return determined along the first axis of the foam articlehaving a change from an energy return in a first axis of the referencefoam article, when determined in accordance with Efficiency Test Method,from about 1.0 percent to about 70 percent; or about 2.5 percent toabout 65 percent; or about 5 percent to about 55 percent; or about 7.5percent to about 50 percent; or about 10 percent to about 45 percent; orabout 12.5 percent to about 45 percent; or about 15 percent to about 45percent; or about 17.5 percent to about 45 percent; or about 20 percentto about 45 percent; or about 2.5 percent to about 55; or about 2.5percent to about 45 percent; or about 2.5 percent to about 40 percent;or about 2.5 percent to about 35 percent; or about 2.5 percent to about30 percent; or about 2.5 percent to about 25 percent; or about 1 percentto about 50 percent; or about 1 percent to about 45 percent; or about 1percent to about 40 percent.

Aspect 33. The foam article of article of Aspect 32, wherein there issubstantially no change in an energy return determined along the secondaxis, the third axis, or both the second and third axes of the foamarticle compared to an energy return determined along the second axis,third axis, or both the second and third axes of the reference foamarticle.

Aspect 34. The foam article of article of Aspect 32 or Aspect 33,wherein there is a decrease in an energy return determined along thesecond axis, the third axis, or both the second and third axes of thefoam article compared to an energy return determined along the secondaxis, third axis, or both the second and third axes of the referencefoam article.

Aspect 35. The foam article of article of any one of Aspect 32-Aspect34, wherein an energy return of the foam article determined along thesecond axis, the third axis, or both the second and third axes is lessthan or equal to an energy return determined along the first axis of thefoam article.

Aspect 36. The foam article of article of Aspect 35, wherein the energyreturn of the foam article determined along the first axis is at leastabout 5 percent greater, or at least about 10 percent greater, or atleast about 20 percent greater than the energy return of the foamarticle determined along the second axis, the third axis, or both thesecond and third axes of the foam article.

Aspect 37. The foam article of any one of Aspect 1-Aspect 17, whereinthe physical property is stiffness.

Aspect 38. The foam article of Aspect 37, wherein a plaque sampleprepared from the foam article exhibits a stiffness value in the firstaxis of the foam article when determined in accordance with EfficiencyTest Method is from about 300 kilopascals to about 2000 kilopascals; orabout 300 kilopascals to about 1500 kilopascal; or about 300 kilopascalsto about 1000 kilopascal; or about 300 kilopascals to about 750kilopascal.

Aspect 39. The foam article of Aspect 37, wherein the foam articleexhibits a stiffness value in the first axis of the foam article, whendetermined in accordance with Efficiency Test Method, is from about 30newtons per millimeter to about 300 newtons per millimeter; or about 50newtons per millimeter to about 300 newtons per millimeter; or about 100newtons per millimeter to about 300 newtons per millimeter; or about 150newtons per millimeter to about 300 newtons per millimeter.

Aspect 40. The foam article of any one of Aspect 37-Aspect 39, wherein areference foam article is compression molded and comprises essentiallythe same polymeric material and has substantially the same density asthe foam article; and wherein the reference foam article has asubstantially isotropic cell shape; and wherein the foam articleexhibits a stiffness value that is that is lower than a reference foamarticle, when determined in accordance with Efficiency Test Method, byabout 5 percent; or about 10 percent; or about 15 percent; or about 20percent; or about 25 percent; or about 30 percent; or about 35 percent;or about 40 percent; or about 45 percent; or about 50 percent.

Aspect 41. The foam article of any one of Aspects 1-Aspect 40, whereinthe elastomeric material comprises one or more polymers.

Aspect 42. The foam article of Aspect 41, wherein the one or morepolymers comprise one or more aliphatic polymers, aromatic polymers, ormixture of both.

Aspect 43. The foam article of Aspect 41 or Aspect 42, wherein the oneor more polymers comprise a homopolymer, a copolymer, a terpolymer, ormixtures of thereof.

Aspect 44. The foam article of any one of Aspect 41-Aspect 43, whereinthe one or more polymers comprise a random copolymer, a blockcopolymers, an alternating copolymer, a periodic copolymer, or a graftcopolymer.

Aspect 45. The foam article of any one of Aspect 41-Aspect 44, whereinthe one or more polymers comprise an elastomer.

Aspect 46. The foam article of any one of Aspect 41-Aspect 45, whereinthe one or more polymers comprise an olefinic polymer.

Aspect 47. The foam article of Aspect 46, wherein the olefinic polymeris an olefinic homopolymer, an olefinic copolymer, or mixtures thereof.

Aspect 48. The foam article of Aspect 46 or Aspect 47, wherein theolefinic polymer comprises a polyethylene, a polypropylene, orcombinations thereof.

Aspect 49. The foam article of any one of Aspect 46-Aspect 48, whereinthe olefinic polymer comprises a polyethylene homopolymer.

Aspect 50. The foam article of Aspect 49, wherein the polyethylenecomprises a low density polyethylene, a high density polyethylene, a lowmolecular weight polyethylene, an ultra-high molecular weightpolyethylene, a linear polyethylene, a branched chain polyethylene, orcombinations thereof.

Aspect 51. The foam article of Aspect 49 or Aspect 50, wherein thepolyethylene comprises an ethylene copolymer.

Aspect 52. The foam article of any one of Aspect 49-Aspect 51, whereinthe polyethylene comprises an ethylene-vinyl acetate (EVA) copolymer, anethylene-vinyl alcohol (EVOH) copolymer, an ethylene-ethyl acrylatecopolymer, an ethylene-unsaturated mono-fatty acid copolymer, orcombinations thereof.

Aspect 53. The foam article of any one of Aspect 41-Aspect 52, whereinthe one or more polymers comprise a polyacrylate.

Aspect 54. The foam article of Aspect 53, wherein the polyacrylatecomprises a polyacrylic acid, an ester of a polyacrylic acid, apolyacrylonitrile, a polyacrylic acetate, a polymethyl acrylate, apolyethyl acrylate, a polybutyl acrylate, a polymethyl methacrylate, apolyvinyl acetate, derivatives thereof, copolymers thereof, or anymixture thereof.

Aspect 55. The foam article of any one of Aspect 41-Aspect 54, whereinthe one or more polymers comprise an ionomeric polymer.

Aspect 56. The foam article of Aspect 55, wherein the ionomeric polymercomprises a polycarboxylic acid or a derivative of a polycarboxylicacid.

Aspect 57. The foam article of Aspect 55 or Aspect 56, wherein theionomeric polymer is a sodium salt, a magnesium salt, a potassium salt,or a salt of another metallic ion.

Aspect 58. The foam article of any one of Aspect 55-Aspect 57, whereinthe ionomeric polymer comprises a fatty acid modified ionomeric polymer.

Aspect 59. The foam article of Aspect 55, wherein the ionomeric polymercomprises a polystyrene sulfonate, an ethylene-methacrylic acidcopolymer, or mixtures thereof.

Aspect 60. The foam article of any one of Aspect 41-Aspect 59, whereinthe one or more polymers comprise a polycarbonate.

Aspect 61. The foam article of any one of Aspect 41-Aspect 60, whereinthe one or more polymers comprise a fluoropolymer.

Aspect 62. The foam article of any one of Aspect 41-Aspect 61, whereinthe one or more polymers comprise a polysiloxane.

Aspect 63. The foam article of any one of Aspect 41-Aspect 62, whereinthe one or more polymers comprise a vinyl polymer.

Aspect 64. The foam article of Aspect 63, wherein the vinyl polymer is apolyvinyl chloride (PVC), a polyvinyl acetate, a polyvinyl alcohol, orcombinations thereof.

Aspect 65. The foam article of any one of Aspect 41-Aspect 64, whereinthe one or more polymers comprise a polystyrene.

Aspect 66. The foam article of Aspect 65, wherein the polystyrenecomprises a styrene copolymer.

Aspect 67. The foam article of Aspect 66, wherein the styrene copolymercomprises a acrylonitrile butadiene styrene (ABS) copolymer, a styreneacrylonitrile (SAN) copolymer, a styrene butadiene styrene (SBS)copolymer, a styrene ethylene butadiene styrene (SEBS) copolymer, astyrene ethylene propylene styrene (SEPS) copolymer, or combinationsthereof.

Aspect 68. The foam article of any one of Aspect 41-Aspect 67, whereinthe one or more polymers comprise a polyamide (PA).

Aspect 69. The foam article of Aspect 68, wherein the polyamidecomprises a PA 6, PA 66, PA 11, a copolymer thereof, or mixturesthereof.

Aspect 70. The foam article of any one of Aspect 41-Aspect 69, whereinthe one or more polymers comprise a polyester.

Aspect 71. The foam article of Aspect 70, wherein the polyestercomprises an aliphatic polyester homopolymer, an aliphatic polyestercopolymer, or mixtures thereof.

Aspect 72. The foam article of Aspect 71, wherein the polyestercomprises a polyglycolic acid, a polylactic acid, a polycaprolactone, apolyhydroxybutyrate, a derivative thereof, or mixtures thereof.

Aspect 73. The foam article of Aspect 72, wherein the polyestercomprises a semi-aromatic copolymer.

Aspect 74. The foam article of Aspect 73, wherein the semi-aromaticcopolymer comprises a polyethylene terephthalate (PET), a polybutyleneterephthalate (PBT), a derivative thereof, or mixtures thereof.

Aspect 75. The foam article of any one of Aspect 41-Aspect 74, whereinthe one or more polymers comprise a polyether.

Aspect 76. The foam article of Aspect 75, wherein the polyethercomprises a polyethylene glycol, a polypropylene glycol, copolymersthereof, derivatives thereof, or mixtures thereof.

Aspect 77. The foam article of any one of Aspect 41-Aspect 76, whereinthe one or more polymers comprise a polyurethane.

Aspect 78. The foam article of Aspect 77, wherein the polyurethanecomprises an aromatic polyurethane derived from an aromatic isocyanate.

Aspect 79. The foam article of Aspect 78, wherein the aromaticisocyanate comprises a diphenylmethane diisocyanate (MDI), a toluenediisocyanate (TDI), or mixtures thereof.

Aspect 80. The foam article of Aspect 77, wherein the polyurethanecomprises an aliphatic polyurethane derived from an aliphaticisocyanate.

Aspect 81. The foam article of Aspect 80, wherein the aliphaticisocyanate comprises a hexamethylene diisocyanate (HDI), isophonediisocyanate (IPDI), or mixtures thereof.

Aspect 82. The foam article of any one Aspect 78-Aspect 81, wherein thepolyurethane comprises a mixture of an aromatic polyurethane and analiphatic polyurethane.

Aspect 83. The foam article of any one of Aspect 41-Aspect 82, whereinthe one or more polymers comprise an epoxy polymer.

Aspect 84. The foam article of any one of Aspect 41-Aspect 83, whereinthe one or more polymers comprise one or more elastomeric polymers.

Aspect 85. The foam article of any one of Aspect 41-Aspect 84, whereinthe one or more polymers comprise one or more thermoplastic polymers.

Aspect 86. The foam article of any one of Aspect 41-Aspect 85, whereinthe one or more polymers comprise one or more thermoplastic elastomericpolymers.

Aspect 87. The foam article of any one of Aspect 41-Aspect 86, whereinthe elastomeric material comprises cross-linked polymers.

Aspect 88. The foam article of any one of Aspect 41-Aspect 87, whereinthe elastomeric material further comprises one or more fillers.

Aspect 89. The foam article of Aspect 88, wherein the filler comprisesglass fibers, powdered glass, modified silica, natural silica, calciumcarbonate, mica, paper, cellulosic material, wood chips, modified clays,natural clays, modified synthetic clays, unmodified synthetic clays,talc, or combinations thereof.

Aspect 90. The foam article of any one of Aspect 1-Aspect 89, whereinthe foam article has a density of about 0.10 grams per cubic centimeterto about 0.35 grams per cubic centimeter; or about 0.15 grams per cubiccentimeter to about 0.30 grams per cubic centimeter; or about 0.15 gramsper cubic centimeter to about 0.25 grams per cubic centimeter; or about0.15 grams per cubic centimeter to about 0.20 grams per cubiccentimeter; or about 0.20 grams per cubic centimeter to about 0.30 gramsper cubic centimeter.

Aspect 91. The foam article of any one of Aspect 1-Aspect 90, whereinthe foam article comprise cells having an average length in the longestdimension of about 10 micrometer to about 2000 micrometer.

Aspect 92. The foam article of any one of Aspect 1-Aspect 91, whereinthe foam article is a cushioning element.

Aspect 93. The foam article of Aspect 92, wherein the cushioning elementis configured to have a majority of force applied in a first directionduring use; and wherein the first axis is parallel to the firstdirection.

Aspect 94. The foam article of Aspect 92 or Aspect 93, wherein thecushioning element is for apparel, footwear, or sporting equipment.

Aspect 95. The foam article of any one of Aspect 92-Aspect 94, whereinthe cushioning element is for footwear.

Aspect 96. The foam article of Aspect 95, wherein the cushioning elementfor footwear comprises a midsole.

Aspect 97. The foam article of Aspect 95, wherein the cushioning elementfor footwear comprises a sockliner.

Aspect 98. The foam article of article of Aspect 92, wherein an x-yplane comprises a plane comprising the second axis and the third axis;wherein the second axis is oriented from a heel edge to a toe edge ofthe midsole and the third axis is oriented from a left lateral edge to aright lateral edge of the midsole; wherein the first axis is orientedperpendicular to a ground-facing portion of the midsole; and wherein thex-y plane is parallel to the ground-facing portion of the midsole.

Aspect 99. An article comprising the foam article of any one of Aspect1-Aspect 98.

Aspect 100. The article of Aspect 99, wherein the article is an articleof footwear, a component of an article of footwear, an article ofapparel, a component of an article of apparel, an article of sportingequipment, or a component of an article of sporting equipment.

Aspect 101. The article of Aspect 100, wherein the article is an articleof footwear.

Aspect 102. The article of Aspect 101, wherein the article of footwearis a shoe, a boot, or a sandal.

Aspect 103. The article of Aspect 102, wherein the article of footwearis a shoe.

Aspect 104. The article of Aspect 103, wherein the shoe is an athleticshoe.

Aspect 105. The article of Aspect 104, wherein the athletic shoe is abaseball shoe, a basketball shoe, a soccer shoe, a football shoe, arunning shoe, a cross-trainer shoe, a track shoe, or a golf shoe.

Aspect 106. The article of Aspect 100, wherein the article is acomponent of an article of footwear.

Aspect 107. The article of Aspect 106, wherein the component of anarticle of footwear is a cushioning element.

Aspect 108. The article of Aspect 107, wherein the cushioning element isconfigured to have a majority of force applied in a first directionduring use; and wherein the first axis is parallel to the firstdirection.

Aspect 109. The article of Aspect 107 or Aspect 108, wherein thecushioning element for footwear comprises a midsole.

Aspect 110. The article of Aspect 107 or Aspect 108, wherein thecushioning element for footwear comprises a sockliner.

Aspect 111. The article of Aspect 100, wherein the article is an articleof sporting equipment or a component of an article of sportingequipment.

Aspect 112. The article of Aspect 111, wherein the article is acomponent of an article of sporting equipment.

Aspect 113. The article of Aspect 112, where the component of an articleof sporting equipment is a cushioning element.

Aspect 114. The article of Aspect 112 or Aspect 113, wherein thecomponent of an article of sporting equipment selected from the groupincluding a component of a hat, a component of a bag, a component of aball, and a component of protective equipment.

Aspect 115. The article of Aspect 100, wherein the article is acomponent of an article of apparel.

Aspect 116. The article of Aspect 115, wherein the component of anarticle of apparel is a cushioning element.

Aspect 117. A method of making a compression molded foam article, themethod comprising: arranging a preform in a compression mold; whereinthe preform comprises a polymeric foam material having a closed cellfoam structure; wherein the preform is associated with a preform x-axis,y-axis, and z-axis such that each axis is perpendicular to the othertwo; wherein the preform has a preform longitudinal dimension parallelto the preform y-axis of a preform x-y plan; wherein the preform z-axisis parallel to the direction of compression applied to the compressionmold; wherein the preform has a preform height that is a dimensionparallel to the preform z-axis; wherein the preform has an initialpreform height equal to the preform height prior to compression molding;wherein the preform has a preform area comprising an area of a preformx-y plane; and wherein the preform has an initial preform area that isthe preform area prior to compression molding; wherein the compressionmold comprises a mold cavity; and wherein the mold cavity is associatedwith a mold cavity x-axis, y-axis, and z-axis such that each axis isperpendicular to the other two; wherein the mold cavity has a moldcavity longitudinal dimension parallel to the mold cavity y-axis of amold cavity x-y plane; wherein the mold cavity z-axis is parallel to thedirection of compression applied to the compression mold; wherein themold cavity has a mold cavity height that is a dimension parallel to thepreform z-axis when the mold is closed; wherein the mold cavity has amold cavity area corresponding to an area of a mold cavity bottom; andwherein the mold cavity bottom is a mold cavity x-y plane opposite amold cavity opening; wherein the initial preform area is less than about95 percent the mold cavity area; wherein the arranging comprisesaligning the preform x-axis, y-axis, and z-axis with the mold cavityx-axis, y-axis, and z-axis; and wherein the initial preform height isfrom about 1.1- to about 5-fold greater than the mold cavity height;closing the compression mold and compressing the preform into a closedmold cavity; applying heat, pressure, or a combination of both to theclosed mold cavity for a duration of time to: (a) alter at least onepreform dimension in the preform x-axis, y-axis, and z-axis; and (b)alter the closed cell foam structure to a closed cell foam structurehaving a greater proportion of anisotropic cell shapes; opening thecompression mold after the least one preform dimension in the preformx-axis, y-axis, and z-axis and the closed cell foam structure arealtered; removing the compression molded foam article from thecompression mold; and forming the compression molded foam article;wherein the compression molded foam article retains dimensions of theclosed mold cavity within about plus or minus 50 percent; and whereinthe compression molded foam article has a closed cell foam structurehaving a greater proportion of closed cells with anisotropic cell shapesas compared to the preform closed cell foam structure, or havingsubstantially the same proportion of closed cells with the anisotropiccells shapes as compared to the preform, where an average aspect ratioof the proportion of the closed cells with the anisotropic cell shapesis greater as comparted to the preform, or both the proportion and theaspect ratio of closed cells with the anisotropic cell shapes aregreater in the foam structure of the compression molded foam article ascompared to the foam structure of the preform.

Aspect 118. The method of Aspect 116, wherein a region of thecompression molded foam article includes the greater proportion ofclosed cells with the anisotropic cell shapes, or includes the closedcells with the greater aspect ratio, or both, and the region occupies atleast 1 cubic centimeter, or at least 3 cubic centimeters, or at least 5cubic centimeters of a total volume of the compression molded foamarticle, and wherein the region does not include an external skin offoam article.

Aspect 119. The method of Aspect 116 or Aspect 118, wherein the initialpreform area is a percent of the cavity area that is less than about 90percent; or about 85 percent; or about 75 percent; or than about 70percent; or about 65 percent; or about 60 percent; or about 50 percent;or about 40 percent.

Aspect 120. The method of any of one of Aspect 116-Aspect 119 whereinthe compression molded foam article retains dimensions of the closedmold cavity within about plus or minus 45 percent; or about plus orminus 30 percent; or about plus or minus 25 percent; or about plus orminus 20 percent; or about plus or minus 15 percent; or about plus orminus 10 percent.

Aspect 121. The method of any of one of Aspect 116-Aspect 120, whereinthe compressing the preform into the closed mold cavity comprisescompressing the preform until a final preform height and a final preformarea are reached; wherein the final preform height is the preform heightwhen it is about equal to the mold cavity height; and wherein the finalpreform area is the preform area when it is about equal to the moldcavity area.

Aspect 122. The method of any of one of Aspect 116-Aspect 121, whereinthe mold cavity area is an average mold cavity area representing anaverage of a first mold cavity area, a second mold cavity area, and athird mold cavity area; wherein the first mold cavity area, the secondmold cavity area, and the third mold cavity area are each an area of anindependent x-y plane located perpendicular to an axis parallel to adirection in which the compression is applied during compressionmolding; and wherein the x-y planes are distributed evenly the axisparallel to a direction in which the compression is applied duringcompression molding.

Aspect 123. The method of any of one of Aspect 116-Aspect 122, whereinthe initial preform area is an average initial preform area representingan average of a first initial preform area, a second initial preformarea, and a third initial preform area; and wherein the first initialpreform area, the second initial preform area, and the third initialpreform cavity area are each an area of an independent x-y plane locatedperpendicular to an axis parallel to a direction in which thecompression is applied during compression molding; and wherein the x-yplanes are distributed evenly the axis parallel to a direction in whichthe compression is applied during compression molding.

Aspect 124. The method of any of one of Aspect 116-Aspect 123, whereinthe final preform area is an average final preform area representing anaverage of a first final preform area, a second final preform area, anda third final preform area; and wherein the first final preform area,the second final preform area, and the third final preform cavity areaare each an area of an independent x-y plane located perpendicular to anaxis parallel to a direction in which the compression is applied duringcompression molding; and wherein the x-y planes are distributed evenlythe axis parallel to a direction in which the compression is appliedduring compression molding.

Aspect 125. The method of any of one of Aspect 116-Aspect 124, furthercomprising compressing the preform until a compression ratio of about1.2 to about 4.0 is achieved; wherein the compression ratio is a ratioof initial preform height to mold cavity depth; wherein the initialpreform height is an average height of the preform determined along anaxis oriented parallel to the direction in which the compression isapplied during compression molding before compression molding; whereinthe initial preform height is determined prior to compression molding;and wherein the mold cavity depth is the average depth of the cavitydetermined along an axis oriented parallel to the direction in which thecompression is applied during compression molding.

Aspect 126. The method of any of one of Aspect 116-Aspect 125, whereinthe polymeric material of the preform comprises an elastomeric material.

Aspect 127. The method of any of one of Aspect 116-Aspect 126, whereinthe preform has a closed cell foam structure that is substantiallyisotropic.

Aspect 128. The method of any of one of Aspect 116-Aspect 126, whereinthe preform has a closed cell foam structure that is less than about 30%anisotropic.

Aspect 129. The method of Aspect 128, wherein the preform has a closedcell foam structure that is less than about 20% anisotropic.

Aspect 130. The method of Aspect 128, wherein the preform has a closedcell foam structure that is less than about 10% anisotropic.

Aspect 131. The method of any of one of Aspect 116-Aspect 130, whereinthe compression molded foam article has a closed cell foam structurethat is substantially anisotropic.

Aspect 132. The method of any of one of Aspect 116-Aspect 131, furthercomprising crosslinking the polymeric material of the preform while thepreform is in the closed mold.

Aspect 133. The method of Aspect 132, wherein the crosslinking thepolymeric material of the preform comprises adding a crosslinking agentprior to the closing the compression mold and compressing the preforminto a closed mold cavity.

Aspect 134. The method of any of one of Aspect 116-Aspect 131, furthercomprising increasing crosslinking of the polymeric material of thepreform while the preform is in the closed mold.

Aspect 135. The method of any of one of Aspect 116-Aspect 132, whereinthe compression molded foam article comprises an elastomeric material.

Aspect 136. The method of Aspect 135, wherein the elastomeric materialof the compression molded foam article and the polymeric material of thefoam preform are compositionally the same.

Aspect 137. A method of making a compression molded foam article, themethod comprising: arranging a preform in a compression mold; whereinthe preform comprises a polymeric material having a closed cell foamstructure; wherein the preform is associated with a preform x-axis,y-axis, and z-axis such that each axis is perpendicular to the othertwo; wherein the preform has a preform longitudinal dimension parallelto the preform y-axis of a preform x-y plan; wherein the preform z-axisis parallel to the direction of compression applied to the compressionmold; wherein the preform has a plurality of initial preform widths;wherein each initial preform width of the plurality of initial preformwidths is designated as IPW_(i); wherein i is an integer having a valueof 1 to 100; and wherein each IPW_(i) has a dimension parallel to thepreform x-axis of the preform x-y plane at a position, Y_(i), along thepreform longitudinal dimension prior to compression molding; wherein thepreform has a preform height; wherein the preform height is a dimensionparallel to the preform z-axis; and wherein the initial preform heightis the preform height prior to compression molding; wherein thecompression mold comprises a mold cavity associated with a mold cavityx-axis, y-axis, and z-axis such that each axis is perpendicular to theother two; wherein the mold cavity has a longitudinal dimension parallelto the mold cavity y-axis of a mold cavity x-y plane; wherein the moldcavity z-axis is parallel to the direction of compression applied to thecompression mold; wherein the mold cavity has a plurality of mold cavitywidths; wherein each mold cavity width of the plurality of mold cavitywidths is designated as CM wherein j is an integer having a value of 1to 100; wherein each CW_(j) has a dimension parallel to the mold cavityx-axis of the mold cavity x-y plane of the preform at a position, P_(j),along the mold cavity longitudinal dimension; wherein the mold cavityhas a mold cavity height that is a dimension parallel to the preformz-axis when the mold is closed; wherein the arranging comprises aligningthe preform x-axis, y-axis, and z-axis with the mold cavity x-axis,y-axis, and z-axis; wherein each P_(i) is associated with acorresponding position of the preform longitudinal dimension when thepreform y-axis and the mold cavity y-axis are aligned; wherein theinitial preform height is from about 1.1- to about 5-fold greater thanthe mold cavity height; wherein the preform and the mold cavity areassociated with a plurality of mold gaps; wherein each mold gap of theplurality of mold gaps is designated as MG_(k); wherein k is an integerhaving a value of 1 to 100; wherein each MG_(k) is obtained from thefollowing equation:

${MG_{k}} = \frac{{CW}_{j} - {IPW}_{i}}{{CW}_{j}}$

and wherein each mold gap is independently from about 0.1 to about 0.7;closing the compression mold and compressing the preform into a closedmold cavity; applying heat, pressure, or a combination of both to theclosed mold cavity for a duration of time to: (a) alter at least onepreform dimension in the preform x-axis, y-axis, and z-axis; and (b)alter the closed cell foam structure of the preform to having a greaterproportion of anisotropic cell shape; opening the compression mold afterthe least one preform dimension in the preform x-axis, γ-axis, andz-axis and the closed cell foam structure are altered; removing thecompression molded foam article from the compression mold; and forming acompression molded foam article; wherein the compression molded foamarticle retains dimensions of the closed mold cavity within about plusor minus 50 percent; and wherein the compression molded foam article hasa closed cell foam structure having a greater proportion of closed cellswith anisotropic cell shapes as compared to the preform closed cell foamstructure, or having substantially the same proportion of closed cellswith the anisotropic cells shapes as compared to the preform, where anaverage aspect ratio of the proportion of the closed cells with theanisotropic cell shapes is greater as comparted to the preform, or boththe proportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the foam structure of the compression moldedfoam article as compared to the foam structure of the preform.

Aspect 138. The method of Aspect 137, wherein a region of thecompression molded foam article includes the greater proportion ofclosed cells with the anisotropic cell shapes, or includes the closedcells with the greater aspect ratio, or both, and the region occupies atleast 1 cubic centimeter, or at least 3 cubic centimeters, or at least 5cubic centimeters of a total volume of the compression molded foamarticle, and wherein the region does not include an external skin offoam article.

Aspect 139. The method of Aspect 137, wherein each mold gap, MGk, isindependently from about 0.125 to about 0.625; or about 0.150 to about0.625; 0.200 to about 0.625; 0.225 to about 0.625; or 0.250 to about0.625; or 0.300 to about 0.625; or 0.325 to about 0.625; or 0.400 toabout 0.625; or 0.500 to about 0.625.

Aspect 140. The method of any of one of Aspect 137-Aspect 139, whereinthe plurality of mold gaps comprise a mold gap, MGk, having a value thatis about equal to a value of a mold gap, MGk+1, a value that isindependently different from a value of a mold gap, MGk+1, orcombinations thereof.

Aspect 141. The method of any of one of Aspect 137-Aspect 140, whereinthe plurality of mold gaps comprise individual mold gaps that areindependently different from one another, substantially equal to oneanother, or combinations thereof.

Aspect 142. The method of any of one of Aspect 137-Aspect 141, whereineach MGk can independently have a different value.

Aspect 143. The method of any of one of Aspect 137-Aspect 142, whereineach MGk is about the same value.

Aspect 144. The method of any of one of Aspect 137-Aspect 143, whereinthe compressing the preform into the closed mold cavity comprisescompressing the preform until a final preform height and a plurality offinal preform widths is reached; wherein the final preform height is thepreform height when it is about equal to the mold cavity height; whereineach final preform width of the plurality of final preform widths isdesignated as FPWi; wherein i is an integer having a value of 1 to m;wherein each FPWi has a dimension parallel to an x-axis of the x-y planeof the preform at a position, Yi, along the preform longitudinaldimension; and wherein the plurality of final preform widths is reachedwhen each FPWi is about equal to each corresponding CWj.

Aspect 145. The method of any of one of Aspect 137-Aspect 144, furthercomprising compressing the preform until a compression ratio of about1.2 to about 4.0 is achieved; wherein the compression ratio is a ratioof average initial preform height to average mold cavity depth; whereinthe average initial preform height is an average height of the preformdetermined along an axis oriented parallel to the direction in which thecompression is applied during compression molding before compressionmolding; wherein the average initial preform height is determined priorto compression molding; and wherein the mold cavity depth is the averagedepth of the cavity determined along an axis oriented parallel to thedirection in which the compression is applied during compressionmolding.

Aspect 146. The method of any of one of Aspect 137-Aspect 145, whereinthe polymeric material of the preform comprises an elastomeric material.

Aspect 147. The method of any of one of Aspect 137-Aspect 146, whereinthe preform has a closed cell foam structure that is substantiallyisotropic.

Aspect 148. The method of any of one of Aspect 137-Aspect 147, whereinthe compression molded foam article has a closed cell foam structurethat is a substantially anisotropic.

Aspect 149. The method of any of one of Aspect 137-Aspect 148, furthercomprising crosslinking the polymeric material of the preform while thepreform is in the closed mold.

Aspect 150. The method of Aspect 149, wherein the crosslinking thepolymeric material of the preform comprises adding a crosslinking agentprior to the closing the compression mold and compressing the preforminto a closed mold cavity.

Aspect 151. The method of any of one of Aspect 137-Aspect 150, furthercomprising increasing crosslinking of the polymeric material of thepreform while the preform is in the closed mold.

Aspect 152. The method of any of one of Aspect 137-Aspect 151, whereinthe compression molded foam article comprises an elastomeric material.

Aspect 153. The method of Aspect 152, wherein the elastomeric materialof the compression molded foam article and the polymeric material of thefoam preform are compositionally the same.

Aspect 154. A method of making a compression molded foam article, themethod comprising: arranging a preform in a compression mold; whereinthe preform comprises a polymeric material having a closed cell foamstructure; wherein the preform is associated with a preform x-axis,y-axis, and z-axis such that each axis is perpendicular to the othertwo; wherein the preform has a preform longitudinal dimension parallelto the preform y-axis of a preform x-y plan; wherein the preform z-axisis parallel to the direction of compression applied to the compressionmold; wherein the preform has a preform height that is a dimensionparallel to the preform z-axis; wherein the preform has an initialpreform height equal to the preform height prior to compression molding;wherein the preform has a preform volume; and wherein the preform has aninitial preform volume that is the preform volume prior to compressionmolding; wherein the compression mold comprises a mold cavity; andwherein the mold cavity is associated with a mold cavity x-axis, y-axis,and z-axis such that each axis is perpendicular to the other two;wherein the mold cavity has a longitudinal dimension parallel to themold cavity y-axis of a mold cavity x-y plane; wherein the mold cavityz-axis is parallel to the direction of compression applied to thecompression mold; wherein the mold cavity has a mold cavity height thatis a dimension parallel to the preform z-axis when the mold is closed;wherein the mold cavity has a mold cavity volume associated with themold when it is closed; wherein the arranging comprises aligning thepreform x-axis, y-axis, and z-axis with the mold cavity x-axis, y-axis,and z-axis; wherein the initial preform height is from about 1.1- toabout 5-fold greater than the mold cavity height; wherein less thanabout 90 percent of the mold cavity volume is occupied by the preform;and wherein at least 30 percent of the initial preform volume ispositioned outside the mold cavity; closing the compression mold andcompressing the preform into a closed mold cavity; applying heat,pressure, or a combination of both to the closed mold cavity for aduration of time to: (a) alter at least one preform dimension in thepreform x-axis, y-axis, and z-axis; and (b) alter the closed cell foamstructure of the preform to having a greater proportion of anisotropiccell shape; opening the compression mold after the least one preformdimension in the preform x-axis, y-axis, and z-axis and the closed cellfoam structure are altered; removing the compression molded foam articlefrom the compression mold; and forming a compression molded foamarticle; wherein the compression molded foam article retains dimensionsof the closed mold cavity within about plus or minus 50 percent; andwherein the compression molded foam article has a closed cell foamstructure having a greater proportion of closed cells with anisotropiccell shapes as compared to the preform closed cell foam structure, orhaving substantially the same proportion of closed cells with theanisotropic cells shapes as compared to the preform, where an averageaspect ratio of the proportion of the closed cells with the anisotropiccell shapes is greater as comparted to the preform, or both theproportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the foam structure of the compression moldedfoam article as compared to the foam structure of the preform.

Aspect 155. The method of Aspect 153, wherein a region of thecompression molded foam article includes the greater proportion ofclosed cells with the anisotropic cell shapes, or includes the closedcells with the greater aspect ratio, or both, and the region occupies atleast 1 cubic centimeter, or at least 3 cubic centimeters, or at least 5cubic centimeters of a total volume of the compression molded foamarticle, and wherein the region does not include an external skin offoam article.

Aspect 156. The method of Aspect 154 or Aspect 155, wherein thepolymeric material of the preform comprises an elastomeric material.

Aspect 157. The method of any of Aspect 154-Aspect 157, wherein thepreform has a closed cell foam structure that is substantiallyisotropic.

Aspect 158. The method of any of one of Aspect 154-Aspect 157, whereinthe compression molded foam article has a closed cell foam structurethat is a substantially anisotropic.

Aspect 159. The method of any of one of Aspect 154-Aspect 158, furthercomprising crosslinking the polymeric material of the preform while thepreform is in the closed mold.

Aspect 160. The method of Aspect 159, wherein the crosslinking thepolymeric material of the preform comprises adding a crosslinking agentprior to the closing the compression mold and compressing the preforminto a closed mold cavity.

Aspect 161. The method of any of one of Aspect 154-Aspect 160, furthercomprising increasing crosslinking of the polymeric material of thepreform while the preform is in the closed mold.

Aspect 162. The method of any of one of Aspect 154-Aspect 161, whereinthe compression molded foam article comprises an elastomeric material.

Aspect 163. The method of any of one of Aspect 154-Aspect 162, whereinless than about 85 percent of the mold cavity volume is occupied by thepreform; and wherein at least 45 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 164. The method of any of one of Aspect 154-Aspect 162, whereinless than about 80 percent of the mold cavity volume is occupied by thepreform; and wherein at least 50 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 165. The method of any of one of Aspect 154-Aspect 162, whereinless than about 70 percent of the mold cavity volume is occupied by thepreform; and wherein at least 55 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 166. The method of any of one of Aspect 154-Aspect 162, whereinless than about 65 percent of the mold cavity volume is occupied by thepreform; and wherein at least 60 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 167. The method of any of one of Aspect 154-Aspect 162, whereinless than about 50 percent of the mold cavity volume is occupied by thepreform; and wherein at least 65 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 168. The method of any of one of Aspect 154-Aspect 162, whereinless than about 40 percent of the mold cavity volume is occupied by thepreform; and wherein at least 75 percent of the initial preform volumeis positioned outside the mold cavity.

Aspect 169. The method of any of one of Aspect 154-Aspect 168, whereinthe compressing the preform into the closed mold cavity comprisescompressing the preform until a final preform height and a final preformvolume are reached; wherein the final preform height is the preformheight when it is about equal to the mold cavity height; and wherein thefinal preform volume is the preform volume when it is about equal to themold cavity volume.

Aspect 170. The method of any of one of Aspect 154-Aspect 169, whereinthe applying heat comprises monitoring a core temperature of the preformand a side temperature of the preform; wherein the core temperature ofthe preform is a temperature determined at a geometric center plus orminus 20 percent of the preform; wherein the side temperature is atemperature of the preform determined at an outer edge plus or minus 20percent of the preform; wherein the applying heat is continued until atarget core temperature is reached; and wherein the target coretemperature is the core temperature of the preform is plus or minus 35degrees Celsius of the side temperature of the preform.

Aspect 171. The method of Aspect 170, wherein the target coretemperature is the core temperature of the preform is plus or minus 30degrees Celsius; or plus or minus 25 degrees Celsius; or plus or minus20 degrees Celsius; or plus or minus 15 degrees Celsius; or is plus orminus 10 degrees Celsius of the side temperature of the preform.

Aspect 172. The method of any of one of Aspect 154-Aspect 171, whereinthe target core temperature is about 100 degrees Celsius to about 250degrees Celsius; or about 100 degrees Celsius to about 180 degreesCelsius; or about 125 degrees Celsius to about 180 degrees Celsius; orabout 150 degrees Celsius to about 180 degrees Celsius; or about 110degrees Celsius to about 170 degrees Celsius; or about 115 degreesCelsius to about 165 degrees Celsius; or about 120 degrees Celsius toabout 160 degrees Celsius; or about 125 degrees Celsius to about 155degrees Celsius; or about 125 degrees Celsius to about 150 degreesCelsius; or about 125 degrees Celsius to about 145 degrees Celsius.

Aspect 173. The method of any of one of Aspect 153-Aspect 172, whereinthe applying the heat comprises maintaining the target core temperaturefor a target core temperature time.

Aspect 174. The method of Aspect 173, wherein the target coretemperature time is sufficient that the polymeric material is flowable;and wherein the compression molded foam article retains dimensions ofthe closed mold cavity within about plus or minus 50 percent.

Aspect 175. The method of Aspect 173, wherein the target coretemperature time is sufficient that the polymeric material to flow andfill the mold cavity; and wherein the compression molded foam articleretains dimensions of the closed mold cavity within about plus or minus50 percent.

Aspect 176. The method of Aspect 173, wherein the target coretemperature time is from about 1 sec to about 100 minutes.

Aspect 177. The method of Aspect 176, wherein the target coretemperature is from about 130 degrees Celsius to about 180 degreesCelsius; and wherein the target core temperature time is from about 1minutes to about 10 minutes; or about 2 minutes to about 9 minutes; orabout 2 minutes to about 8 minutes; or about 3 minutes to about 10minutes; or about 3 minutes to about 9 minutes; or about 3 minutes toabout 8 minutes.

Aspect 178. The method of any one of Aspect 170-Aspect 177, furthercomprising cooling the mold after applying heat, pressure, or acombination of both to the closed mold cavity.

Aspect 179. The method of Aspect 178, wherein cooling comprises loweringthe target core temperature until the finished compression molded foamarticle retains the dimensions of the mold when it is closed to aboutplus or minus 10 percent.

Aspect 180. The method of Aspect 178, wherein cooling comprises loweringthe target core temperature by at least about 10 degrees Celsius; or atleast about 20 degrees Celsius; or at least about 30 degrees Celsius.

Aspect 181. The method of Aspect 178, wherein cooling comprises loweringthe target core temperature from about 10 degrees Celsius to about 100degrees Celsius; or about 30 degrees Celsius to about 100 degreesCelsius; or about 50 degrees Celsius to about 100 degrees Celsius; orabout 10 degrees Celsius to about 20 degrees Celsius; or about 10degrees Celsius to about 30 degrees Celsius; or about 10 degrees Celsiusto about 50 degrees Celsius.

Aspect 182. The method of any of one of Aspect 117-Aspect 181, whereinthe greater proportion of cells having an anisotropic cell shapecompared to the preform is based on weight.

Aspect 183. The method of Aspect 182, wherein the compression moldedfoam article has a compression molded foam article weight; and whereinthe greater proportion of cells having an anisotropic cell shapecomprise a percent of the compression molded foam article weight that isfrom about 10 percent to about 100 percent; or about 20 percent to about100 percent; or about 30 percent to about 100 percent; or about 40percent to about 100 percent; or about 50 percent to about 100 percent;or about 60 percent to about 100 percent; or about 70 percent to about100 percent; or about 80 percent to about 100 percent; or about 90percent to about 100 percent; or about 10 percent to about 90 percent;or about 20 percent to about 90 percent; or about 30 percent to about 90percent; or about 40 percent to about 90 percent; or about 50 percent toabout 90 percent; or about 60 percent to about 90 percent; or about 70percent to about 90 percent; or about 80 percent to about 90 percent.

Aspect 184. The method of any of one of Aspect 117-Aspect 181, whereinthe greater proportion of cells having an anisotropic cell shapecompared to the preform is based on volume.

Aspect 185. The method of Aspect 184, wherein the compression moldedfoam article has a compression molded foam article volume; and whereinthe greater proportion of cells having an anisotropic cell shapecomprise a percent of the compression molded foam article volume that isfrom about 10 percent to about 100 percent; or about 20 percent to about100 percent; or about 30 percent to about 100 percent; or about 40percent to about 100 percent; or about 50 percent to about 100 percent;or about 60 percent to about 100 percent; or about 70 percent to about100 percent; or about 80 percent to about 100 percent; or about 90percent to about 100 percent; or 10 percent to about 90 percent; orabout 20 percent to about 90 percent; or about 30 percent to about 90percent; or about 40 percent to about 90 percent; or about 50 percent toabout 90 percent; or about 60 percent to about 90 percent; or 70 percentto about 90 percent; or about 80 percent to about 90 percent.

Aspect 186. The method of any of one of Aspect 117-Aspect 181, whereinthe greater proportion of cells having an anisotropic cell shapecompared to the preform is based on cell number.

Aspect 187. The method of Aspect 186, wherein the compression moldedfoam article has a compression molded foam article cell numberrepresenting a total number of closed cells contained within thecompression molded foam article; and wherein the greater proportion ofcells having an anisotropic cell shape comprise a percent of thecompression molded foam article cell number that is from about 10percent to about 100 percent; or about 30 percent to about 100 percent;about 40 percent to about 100 percent; or about 50 percent to about 100percent; or about 60 percent to about 100 percent; or about 70 percentto about 100 percent; or about 80 percent to about 100 percent; or about90 percent to about 100 percent; or about 10 percent to about 90percent; or about 20 percent to about 90 percent; or about 30 percent toabout 90 percent; or about 40 percent to about 90 percent; or about 50percent to about 90 percent; or about 60 percent to about 90 percent; orabout 70 percent to about 90 percent; or about 80 percent to about 90percent.

Aspect 188. The method of any of one of Aspect 117-Aspect 181, whereinthe compression molded foam article has a compression molded foamarticle average height along an axis parallel to the z-axis; wherein aplurality of cells having an anisotropic shape are distributed along apercent of the foam article average height that is at least about 10percent; or at least about 20 percent; or at least about 30 percent; orat least about 40 percent; or at least about 50 percent; or at leastabout 60 percent; or at least about 70 percent; or at least about 80percent; or at least about 90 percent.

Aspect 189. The method of any of one of Aspect 117-Aspect 188, whereinthe closed cell foam comprises one or more polymers.

Aspect 190. The method of Aspect 189, wherein the one or more polymerscomprise one or more aliphatic polymers, aromatic polymers, or mixtureof both.

Aspect 191. The method of Aspect 189 or Aspect 190, wherein the one ormore polymers comprise a homopolymer, a copolymer, a terpolymer, ormixtures of thereof.

Aspect 192. The method of any one of Aspect 189-Aspect 191, wherein theone or more polymers comprise a random copolymer, a block copolymers, analternating copolymer, a periodic copolymer, or a graft copolymer.

Aspect 193. The method of any one of Aspect 189-Aspect 192, wherein theone or more polymers comprise an elastomer.

Aspect 194. The method of any one of Aspect 189-Aspect 193, wherein theone or more polymers comprise an olefinic polymer.

Aspect 195. The method of Aspect 194, wherein the olefinic polymer is anolefinic homopolymer, an olefinic copolymer, or mixtures thereof.

Aspect 196. The method of Aspect 194 or Aspect 195, wherein the olefinicpolymer comprises a polyethylene, a polypropylene, or combinationsthereof.

Aspect 197. The method of any one of Aspect 194-Aspect 196, wherein theolefinic polymer comprises a polyethylene homopolymer.

Aspect 198. The method of Aspect 197, wherein the PE comprises a lowdensity polyethylene, a high density polyethylene, a low molecularweight polyethylene, an ultra-high molecular weight polyethylene, alinear polyethylene, a branched chain polyethylene, or combinationsthereof.

Aspect 199. The method of Aspect 197 or Aspect 198, wherein thepolyethylene comprises an ethylene copolymer.

Aspect 200. The method of any one of Aspect 197-Aspect 199, wherein thepolyethylene comprises an ethylene-vinyl acetate (EVA) copolymer, anethylene-vinyl alcohol (EVOH) copolymer, an ethylene-ethyl acrylatecopolymer, an ethylene-unsaturated mono-fatty acid copolymer, orcombinations thereof.

Aspect 201. The method of any one of Aspect 189-Aspect 200, wherein theone or more polymers comprise a polyacrylate.

Aspect 202. The method of Aspect 201, wherein the polyacrylate comprisesa polyacrylic acid, an ester of a polyacrylic acid, a polyacrylonitrile,a polyacrylic acetate, a polymethyl acrylate, a polyethyl acrylate, apolybutyl acrylate, a polymethyl methacrylate, a polyvinyl acetate,derivatives thereof, copolymers thereof, or any mixture thereof.

Aspect 203. The method of any one of Aspect 189-Aspect 202, wherein theone or more polymers comprise an ionomeric polymer.

Aspect 204. The method of Aspect 203, wherein the ionomeric polymercomprises a polycarboxylic acid or a derivative of a polycarboxylicacid.

Aspect 205. The method of Aspect 203 or Aspect 204, wherein theionomeric polymer is a sodium salt, a magnesium salt, a potassium salt,or a salt of another metallic ion.

Aspect 206. The method of any one of Aspect 203-Aspect 205, wherein theionomeric polymer comprises a fatty acid modified ionomeric polymer.

Aspect 207. The method of Aspect 203, wherein the ionomeric polymercomprises a polystyrene sulfonate, an ethylene-methacrylic acidcopolymer, or mixtures thereof.

Aspect 208. The method of any one of Aspect 189-Aspect 207, wherein theone or more polymers comprise a polycarbonate.

Aspect 209. The method of any one of Aspect 189-Aspect 208, wherein theone or more polymers comprise a fluoropolymer.

Aspect 210. The method of any one of Aspect 189-Aspect 209, wherein theone or more polymers comprise a polysiloxane.

Aspect 211. The method of any one of Aspect 189-Aspect 210, wherein theone or more polymers comprise a vinyl polymer.

Aspect 212. The method of Aspect 211, wherein the vinyl polymer is apolyvinyl chloride (PVC), a polyvinyl acetate, a polyvinyl alcohol, orcombinations thereof.

Aspect 213. The method of any one of Aspect 189-Aspect 212, wherein theone or more polymers comprise a polystyrene.

Aspect 214. The method of Aspect 213, wherein the polystyrene comprisesa styrene copolymer.

Aspect 215. The method of Aspect 214, wherein the styrene copolymercomprises a acrylonitrile butadiene styrene (ABS) copolymer, a styreneacrylonitrile (SAN) copolymer, a styrene butadiene styrene (SBS)copolymer, a styrene ethylene butadiene styrene (SEBS) copolymer, astyrene ethylene propylene styrene (SEPS) copolymer, or combinationsthereof.

Aspect 216. The method of any one of Aspect 189-Aspect 215, wherein theone or more polymers comprise a polyamide (PA).

Aspect 217. The method of Aspect 216, wherein the polyamide comprises aPA 6, PA 66, PA 11, a copolymer thereof, or mixtures thereof.

Aspect 218. The method of any one of Aspect 189-Aspect 217, wherein theone or more polymers comprise a polyester.

Aspect 219. The method of Aspect 218, wherein the polyester comprises analiphatic polyester homopolymer, an aliphatic polyester copolymer, ormixtures thereof.

Aspect 220. The method of Aspect 219, wherein the polyester comprises apolyglycolic acid, a polylactic acid, a polycaprolactone, apolyhydroxybutyrate, a derivative thereof, or mixtures thereof.

Aspect 221. The method of Aspect 220, wherein the polyester comprises asemi-aromatic copolymer.

Aspect 222. The method of Aspect 221, wherein the semi-aromaticcopolymer comprises a polyethylene terephthalate (PET), a polybutyleneterephthalate (PBT), a derivative thereof, or mixtures thereof.

Aspect 223. The method of any one of Aspect 189-Aspect 222, wherein theone or more polymers comprise a polyether.

Aspect 224. The method of Aspect 223, wherein the polyether comprises apolyethylene glycol, a polypropylene glycol, copolymers thereof,derivatives thereof, or mixtures thereof.

Aspect 225. The method of any one of Aspect 189-Aspect 224, wherein theone or more polymers comprise a polyurethane.

Aspect 226. The method of Aspect 225, wherein the polyurethane comprisesan aromatic polyurethane derived from an aromatic isocyanate.

Aspect 227. The method of Aspect 226, wherein the aromatic isocyanatecomprises a diphenylmethane diisocyanate (MDI), a toluene diisocyanate(TDI), or mixtures thereof.

Aspect 228. The method of Aspect 225, wherein the polyurethane comprisesan aliphatic polyurethane derived from an aliphatic isocyanate.

Aspect 229. The method of Aspect 228, wherein the aliphatic isocyanatecomprises a hexamethylene diisocyanate (HDI), isophone diisocyanate(IPDI), or mixtures thereof.

Aspect 230. The method of Aspect 226-Aspect 229, wherein thepolyurethane comprises a mixture of an aromatic polyurethane and analiphatic polyurethane.

Aspect 231. The method of any one of Aspect 189-Aspect 230, wherein theone or more polymers comprise an epoxy polymer.

Aspect 232. The method of any one of Aspect 189-Aspect 231, wherein theone or more polymers comprise one or more elastomeric polymers.

Aspect 233. The method of any one of Aspect 189-Aspect 232, wherein theone or more polymers comprise one or more thermoplastic polymers.

Aspect 234. The method of any one of Aspect 189-Aspect 233, wherein theone or more polymers comprise one or more thermoplastic elastomericpolymers.

Aspect 235. The method of any one of Aspect 189-Aspect 234, wherein theone or more polymers further comprise cross-links.

Aspect 236. The method of any one of Aspect 189-Aspect 235, wherein theelastomeric foam cell further comprises one or more filler.

Aspect 237. The method of Aspect 236, wherein the filler comprises glassfibers, powdered glass, modified silica, natural silica, calciumcarbonate, mica, paper, cellulosic material, wood chips, modified clays,natural clays, modified synthetic clays, unmodified synthetic clays,talc, or combinations thereof.

Aspect 238. The method of any one of Aspect 117-Aspect 237, wherein theinitial preform height is greater than the mold cavity height by fromabout 1.1- to about 4-fold; or about 1.5- to about 4-fold; or about 2.0-to about 4-fold; or about 2.5- to about 4-fold; or about 3.0- to about4-fold; or about 1.5- to about 5-fold; or about 2.0- to about 5-fold; orabout 2.5- to about 5-fold; or about 3.0- to about 5-fold; or about 3.5-to about 5-fold; or about 4.0- to about 5-fold.

Aspect 239. The method of any one of Aspect 117-Aspect 238, wherein thecompression molded foam article is associated with a compression moldedfoam article x-axis, y-axis, and z-axis such that each axis isperpendicular to the other two; wherein z-axis is parallel to adirection in which compression is applied during the compressing;wherein the x-axis and the y-axis define a plane parallel to a majorsurface of the compression molded foam article; wherein a physicalproperty determined along the z-axis is different from the physicalproperty determined along the x-axis, the y-axis, or both the x-axis andthe y-axis; and wherein having an anisotropic cell shape have an averageaspect ratio that is an average ratio of the y-axis to the z-axis;wherein a major axis is parallel to the y-axis; wherein a minor axis isparallel to the x-axis; and wherein the average aspect ratio is fromabout 1.5 to about 15.

Aspect 240. The method of Aspect 239, wherein the aspect ratio is fromabout 2 to about 15; or about 2.5 to about 15; or about 5 to about 15;or about 7.5 to about 15; or about 10 to about 15; or about 2 to about10; or about 2.5 to about 10; or about 5 to about 10; or about 7.5 toabout 10.

Aspect 241. The method of Aspect 239, wherein the plurality of cellshaving an anisotropic cell shape are aligned in an orientation along thesecond axis within a range of a solid angle of about plus or minus 20degrees; or about plus or minus 15 degrees; or about plus or minus 10degrees; or about plus or minus 5 degrees.

Aspect 242. The method of any one of Aspect 239-Aspect 241, wherein thephysical property is at least one physical property.

Aspect 243. The method of any one of Aspect 239-Aspect 242, wherein thephysical property is efficiency.

Aspect 244. The method of Aspect 243, wherein the efficiency in thez-axis of the compression molded foam article, when determined inaccordance with Efficiency Test Method, is greater than or equal toabout 5 percent; or about 15 percent; or about 20 percent; or about 25percent; or about 30 percent; or about 35 percent; or about 40 percent;or about 45 percent; or about 50 percent; or about 55 percent; or about60 percent; or about 65 percent; or about 65 percent; or about 70percent; or about 75 percent; or about 80 percent; or about 82 percent;or about 84 percent; or about 86 percent; or about 88 percent; or about89 percent; or about 90 percent; or about 91 percent; or about 92percent; or about 93 percent; or about 94 percent; or about 95 percent;or about 96 percent; or about 97 percent; or about 98 percent; or about99 percent; or about 100 percent; or about 150 percent; or about 200percent; or about 250 percent; or about 300 percent; or about 350percent; or about 400 percent; or about 450 percent; or about 500percent; or about 600 percent; or about 700 percent; or about 800percent; or about 900 percent; or about 1000 percent; or about 1500percent; or about 2000 percent; or about 2100 percent; or about 2200percent.

Aspect 245. The method of Aspect 243, wherein the efficiency in thez-axis of the compression molded foam article, when determined inaccordance with Efficiency Test Method, is from about 60 percent toabout 99 percent; or about 65 percent to about 99 percent; or about 70percent to about 99 percent; or about 75 percent to about 99 percent; orabout 80 percent to about 99 percent; or about 82 percent to about 99percent; or about 84 percent to about 99 percent; or about 86 percent toabout 99 percent; or about 88 percent to about 99 percent.

Aspect 246. The method of any one of Aspect 243-Aspect 245, wherein theefficiency of the compression molded foam article determined along thex-axis, the y-axis, or both the x-axis and y-axis is less than or equalto an efficiency determined along the z-axis of the compression moldedfoam article.

Aspect 247. The method of Aspect 246, wherein the efficiency of thecompression molded foam article determined along the z-axis is at least5 percent greater, or at least 10 percent greater, or at least 20percent greater than the efficiency of the compression molded foamarticle determined along the x-axis, the y-axis, or both the x-axis andy-axis of the compression molded foam article.

Aspect 248. The method of Aspect 243, wherein a reference foam articleis compression molded and comprises essentially the same polymericmaterial and has substantially the same density as the compressionmolded foam article; wherein the reference foam article has a closedcell structure that is substantially isotropic; and wherein thecompression molded foam article exhibits an efficiency determined alongthe z-axis of the foam article greater than the reference foam article,when determined in accordance with Efficiency Test Method, by about 1.0percent to about 50 percent; or about 2.5 percent to about 50 percent;or about 5 percent to about 50 percent; or about 7.5 percent to about 50percent; or about 10 percent to about 50 percent; or about 12.5 percentto about 50 percent; or about 15 percent to about 50 percent; or about17.5 percent to about 50 percent; or about 20 percent to about 50percent greater; or about 2.5 percent to about 25 percent; or about 5percent to about 25 percent; or about 7.5 percent to about 25 percent;or about 10 percent to about 25 percent; or about 12.5 percent to about25 percent; or about 15 percent to about 25 percent; or about 17.5percent to about 25 percent; or about 20 percent to about 25 percent; orabout 2.5 percent to about 22.5 percent; or about 2.5 percent to about20 percent; or about 2.5 percent to about 17.5 percent; or about 2.5percent to about 15 percent; or about 2.5 percent to about 10 percent;or about 2.5 percent to about 7.5 percent; or about 1 percent to about 5percent; or about 1 percent to about 7.5 percent; or about 1 percent toabout 10 percent.

Aspect 249. The method of Aspect 248, wherein there is substantially nochange in an efficiency determined along the x-axis, the y-axis, or boththe x-axis and y-axis of the compression molded foam article compared toan efficiency determined along the x-axis, γ-axis, or both the secondand third axes of the reference foam article.

Aspect 250. The method of any one of Aspect 248 or Aspect 249, whereinthere is a decrease in an efficiency determined along the x-axis, they-axis, or both the x-axis and y-axis of the compression molded foamarticle compared to an efficiency determined along the x-axis, y-axis,or both the second and third axes of the reference foam article.

Aspect 251. The method of any one of Aspect 248-Aspect 250, wherein anefficiency of the compression molded foam article determined along thex-axis, the y-axis, or both the x-axis and y-axis is less than or equalto an efficiency determined along the z-axis of the compression moldedfoam article.

Aspect 252. The method of Aspect 251, wherein the efficiency of thecompression molded foam article determined along the z-axis is at least5 percent greater, or at least 10 percent greater, or at least 20percent greater than the efficiency of the compression molded foamarticle determined along the x-axis, the y-axis, or both the x-axis andy-axis of the compression molded foam article.

Aspect 253. The method of any one of Aspect 239-Aspect 252, wherein thephysical property is energy return.

Aspect 254. The method of any one of Aspect 253, wherein a referencefoam article is compression molded and comprising essentially the samepolymeric material and has substantially the same density as thecompression molded foam article; wherein the reference foam article hasa closed cell structure that is substantially isotropic; and wherein thecompression molded foam article exhibits an energy return determinedalong the z-axis of the foam article greater than the reference foamarticle, when determined in accordance with Efficiency Test Method, byfrom about 1.0 percent to about 70 percent; or about 2.5 percent toabout 60 percent; or about 5 percent to about 50 percent; or about 7.5percent to about 50 percent; or about 10 percent to about 50 percent; orabout 12.5 percent to about 50 percent; or about 15 percent to about 50percent; or about 17.5 percent to about 50 percent; or about 20 percentto about 50 percent; or about 2.5 percent to about 40 percent; or about2.5 percent to about 30 percent; or about 2.5 percent to about 25percent; or about 2.5 percent to about 20 percent; or about 2.5 percentto about 17.5 percent; or about 2.5 percent to about 15 percent; orabout 1 percent to about 40 percent; or about 1 percent to about 30percent; or about 1 percent to about 20 percent.

Aspect 255. The method of Aspect 254, wherein an energy return of thecompression molded foam article determined along the x-axis, the y-axis,or both the x-axis and y-axis is less than or equal to an energy returndetermined along the z-axis of the compression molded foam article.

Aspect 256. The method of Aspect 255, wherein the energy return of thecompression molded foam article determined along the z-axis is at least5 percent greater, or at least 10 percent greater, or at least 20percent greater than the energy return of the compression molded foamarticle determined along the x-axis, the y-axis, or both the x-axis andy-axis of the compression molded foam article.

Aspect 257. The method of any one of Aspect 253, wherein a referencefoam article is compression molded foam article and comprisesessentially the same polymeric material and has substantially the samedensity as the compression molded foam article; wherein the referencefoam article has a closed cell structure that is substantiallyisotropic; and wherein the compression molded foam article exhibits anenergy return determined along the z-axis of the compression molded foamarticle having a change from an energy return in a z-axis of thereference foam article, when determined in accordance with EfficiencyTest Method, from about 1.0 percent to about 70 percent; or about 2.5percent to about 65 percent; or about 5 percent to about 55 percent; orabout 7.5 percent to about 50 percent; or about 10 percent to about 45percent; or about 12.5 percent to about 45 percent; or about 15 percentto about 45 percent; or about 17.5 percent to about 45 percent; or about20 percent to about 45 percent; or about 2.5 percent to about 55; orabout 2.5 percent to about 45 percent; or about 2.5 percent to about 40percent; or about 2.5 percent to about 35 percent; or about 2.5 percentto about 30 percent; or about 2.5 percent to about 25 percent; or about1 percent to about 50 percent; or about 1 percent to about 45 percent;or about 1 percent to about 40 percent.

Aspect 258. The method of Aspect 257, wherein there is substantially nochange in an energy return determined along the x-axis, the y-axis, orboth the x-axis and y-axis of the compression molded foam articlecompared to an energy return determined along the x-axis, y-axis, orboth the second and third axes of the reference foam article.

Aspect 259. The method of Aspect 258, wherein there is a decrease in anenergy return determined along the x-axis, the y-axis, or both thex-axis and y-axis of the compression molded foam article compared to anenergy return determined along the x-axis, y-axis, or both the secondand third axes of the reference foam article.

Aspect 260. The method of any one of Aspect 257-Aspect 259, wherein anenergy return of the compression molded foam article determined alongthe x-axis, the y-axis, or both the x-axis and y-axis is less than orequal to an energy return determined along the z-axis of the compressionmolded foam article.

Aspect 261. The method of Aspect 260, wherein the energy return of thecompression molded foam article determined along the z-axis is at least5 percent greater, or at least 10 percent greater, or at least 20percent greater than the energy return of the compression molded foamarticle determined along the x-axis, the y-axis, or both the x-axis andy-axis of the compression molded foam article.

Aspect 262. The method of any one of Aspect 239-Aspect 252, wherein thephysical property is stiffness.

Aspect 263. The method of Aspect 262, wherein a plaque sample preparedfrom the compression molded foam article exhibits a stiffness value inthe z-axis of the compression molded foam article, when determined inaccordance with Efficiency Test Method, is from about 300 kilopascals toabout 2000 kilopascals; or about 300 kilopascals to about 1500kilopascal; or about 300 kilopascals to about 1000 kilopascal; or about300 kilopascals to about 750 kilopascal.

Aspect 264. The method of Aspect 262, wherein the compression moldedfoam article exhibits a stiffness value in the z-axis of the foamarticle, when determined in accordance with Efficiency Test Method, isfrom about 30 newtons per millimeter to about 300 newtons permillimeter; or about 50 newtons per millimeter to about 300 newtons permillimeter; or about 100 newtons per millimeter to about 300 newtons permillimeter; or about 150 newtons per millimeter to about 300 newtons permillimeter.

Aspect 265. The method of any one of Aspect 262-Aspect 264, wherein areference foam article is a compression molded and comprises essentiallythe same polymeric material and has a density that is substantially thesame as the compression molded foam article; wherein the reference foamarticle has a substantially isotropic cell shape; and wherein thecompression molded foam article exhibits a stiffness value that is thatis lower than a reference foam article, when determined in accordancewith Efficiency Test Method, by about 5 percent; or about 10 percent; orabout 15 percent; or about 20 percent; or about 25 percent; or about 30percent; or about 35 percent; or about 40 percent; or about 45 percent;or about 50 percent.

Aspect 266. The method of any one of Aspect 116-Aspect 265, wherein theanisotropic cell shape has an average aspect ratio that is an averageratio of the x-axis to the z-axis; wherein a major axis is parallel tothe x-axis; wherein a minor axis is parallel to the z-axis; and whereinthe average aspect ratio is from about 1.5 to about 15; or is from about2 to about 15; or is from about 2.5 to about 15; or is from about 5 toabout 15; or is from about 7.5 to about 15; or is from about 10 to about15; or is from about 2 to about 10; or is from about 2.5 to about 10; oris from about 5 to about 10; or is from about 7.5 to about 10.

Aspect 267. The method of any one of Aspect 116-Aspect 266, whereinabout 40 percent to about 100 percent; about 50 percent to about 90percent; or about 60 percent to about 90 percent; or about 70 percent toabout 90 percent; or about 80 percent to about 90 percent; about 90percent to about 100 percent of the compression molded foam articlecomprises the anisotropic cell shape.

Aspect 268. The method of any one of Aspect 116-Aspect 267, wherein theanisotropic cell shape is ellipsoid.

Aspect 269. The method of Aspect 268, wherein the anisotropic cell shapeis tri-axial ellipsoid, oblate spheroid, prolate spheroid, or mixturesthereof.

Aspect 270. The method of any one of Aspect 116-Aspect 269, wherein thefoam article has a density of about 0.10 grams per cubic centimeter toabout 0.35 grams per cubic centimeter; or about 0.15 grams per cubiccentimeter to about 0.30 grams per cubic centimeter; or about 0.15 gramsper cubic centimeter to about 0.25 grams per cubic centimeter; or about0.15 grams per cubic centimeter to about 0.20 grams per cubiccentimeter; or about 0.20 grams per cubic centimeter to about 0.30 gramsper cubic centimeter.

Aspect 271. The method of any one of Aspect 116-Aspect 270, wherein thefoam article comprise cells having a length in the longest dimension ofabout 10 micrometer to about 500 micrometer.

Aspect 272. An article comprising the foam article made by the method ofany one of Aspects Aspect 116-Aspect 271.

Aspect 273. The article of Aspect 272, wherein the article is an articleof footwear, a component of an article of footwear, an article ofapparel, a component of an article of apparel, an article of sportingequipment, or a component of an article of sporting equipment.

Aspect 274. The article of Aspect 273, wherein the article is an articleof footwear.

Aspect 275. The article of Aspect 274, wherein the article of footwearis a shoe, a boot, or a sandal.

Aspect 276. The article of Aspect 275, wherein the article of footwearis a shoe.

Aspect 277. The article of Aspect 276, wherein the shoe is an athleticshoe.

Aspect 278. The article of Aspect 277, wherein the athletic shoe is abaseball shoe, a basketball shoe, a soccer shoe, a football shoe, arunning shoe, a cross-trainer shoe, a track shoe, or a golf shoe.

Aspect 279. The article of Aspect 273, wherein the article is acomponent of an article of footwear.

Aspect 280. The article of Aspect 279, wherein the component of anarticle of footwear is a cushioning element.

Aspect 281. The article of Aspect 280, wherein the cushioning element isconfigured to have a majority of force applied in a first directionduring use; and wherein the first axis is parallel to the firstdirection.

Aspect 282. The article of Aspect 280 or Aspect 281, wherein thecushioning element for footwear comprises a midsole.

Aspect 283. The article of Aspect 280 or Aspect 281, wherein thecushioning element for footwear comprises a sockliner.

Aspect 284. The article of Aspect 273, wherein the article is an articleof sporting equipment or a component of an article of sportingequipment.

Aspect 285. The article of Aspect 284, wherein the article is acomponent of an article of sporting equipment.

Aspect 286. The article of Aspect 285, where the component of an articleof sporting equipment is a cushioning element.

Aspect 287. The article of Aspect 284 or Aspect 286, wherein thecomponent of an article of sporting equipment selected from the groupincluding a component of a hat, a component of a bag, a component of aball, and a component of protective equipment.

Aspect 288. The article of Aspect 273, wherein the article is acomponent of an article of apparel.

Aspect 289. The article of Aspect 288, wherein the component of anarticle of apparel is a cushioning element.

Aspect 290. A foam midsole comprising: an elastomeric material having aclosed cell foam structure comprising a plurality of cells having ananisotropic cell shape; wherein the plurality of cells having theanisotropic cell shape are present in a region of the foam midsole thatdoes not include an external skin of the foam midsole, and the regionoccupies at least 1 cubic centimeter of a total volume of the foammidsole; wherein the foam midsole comprises a first axis, a second axisand a third axis; wherein the first axis is perpendicular to the secondaxis and the third axis; wherein the second axis and the third axis areeach perpendicular to each other; and wherein the second and the thirdaxis define a plane parallel to a major surface of the foam article; andwherein an efficiency of the foam midsole determined along the firstaxis is greater than or equal to about 60 percent when determined inaccordance with Efficiency Test Method, and is at least 2 percentgreater than an efficiency of the foam midsole determined along thesecond axis, the third axis, or both the second and third axes.

Aspect 291. The foam midsole of Aspect 290, wherein the foam midsole isa compression molded foam midsole, and the first axis is parallel to adirection in which compression is applied during a compression moldingprocess.

Aspect 292. The foam midsole of Aspect 290 or Aspect 291, wherein theplurality of cells have an average aspect ratio that is an average ratioof the second axis to the first axis; wherein a major axis is parallelto the second axis; wherein a minor axis is parallel to the first axis;and wherein the average aspect ratio is from about 1.5 to about 15.

Aspect 293. The foam midsole of Aspect 292, wherein the average aspectratio is from about 2 to about 10.

Aspect 294. The foam midsole of any one of Aspect 290-Aspect 293,wherein the plurality of cells having an anisotropic cell shape aredispersed throughout the foam midsole.

Aspect 295. The foam midsole of Aspect 294, wherein the plurality ofcells having an anisotropic cell shape are dispersed substantiallyuniformly throughout a height of the foam midsole.

Aspect 296. The foam midsole of Aspect 295, wherein the foam midsole hasa foam midsole average height along an axis parallel to the first axis;wherein the plurality of cells having an anisotropic shape aredistributed along at least 10 percent of the foam midsole averageheight.

Aspect 297. The foam midsole of any one of Aspect 290-Aspect 296,wherein the plurality of cells having an anisotropic cell shapecomprises from about 10 percent to about 100 percent of the foam midsolevolume.

Aspect 298. The foam midsole of any one of Aspect 290-Aspect 296,wherein the plurality of cells having an anisotropic cell shapecomprises from about 10 percent to about 100 percent of the foam midsoleweight.

Aspect 299. The foam midsole of any one of Aspect 290-Aspect 296,wherein the plurality of cells having an anisotropic cell shapecomprises from about 10 percent to about 100 percent of the foam midsolecell number.

Aspect 300. The foam midsole of any one of Aspect 290-Aspect 299,wherein the foam midsole exhibits an efficiency as determined along thefirst axis of the foam article of from about 1.0 percent to about 30percent greater than a reference foam article when determined inaccordance with Efficiency Test Method; wherein the reference foamarticle is a compression molded foam article comprising essentially thesame polymeric material and having a substantially same density as thefoam midsole; and wherein the reference foam article has a closed cellstructure that is substantially isotropic.

Aspect 301. The foam midsole of any one of Aspect 290-Aspect 299,wherein the foam midsole exhibits an energy return as determined alongthe first axis of from about 1.0 percent to about 70 percent greaterthan a reference foam article when determined in accordance withEfficiency Test Method; wherein the reference foam article is acompression molded foam article comprising essentially the samepolymeric material and having a density that is substantially the sameas the foam midsole; and wherein the reference foam article has a closedcell structure that is substantially isotropic.

Aspect 302. The foam midsole of any one of Aspect 290-Aspect 301,wherein a plaque sample prepared from the foam midsole exhibits astiffness value in the first axis of the foam article from about 300kilopascals to about 2000 kilopascals when determined in accordance withEfficiency Test Method.

Aspect 303. The foam midsole of any one of Aspect 290-Aspect 302,wherein the foam midsole exhibits a stiffness value that is about 5percent lower than a reference foam article when determined inaccordance with Efficiency Test Method; wherein the reference foamarticle is a compression molded foam article comprising essentially thesame polymeric material and having a density that is substantially thesame as the foam midsole; and wherein the reference foam article has asubstantially isotropic cell shape.

Aspect 304. The foam midsole of any one of Aspect 290-Aspect 303,wherein the polymeric material comprises one or more elastomers.

Aspect 305. The foam midsole of any one of Aspect 290-Aspect 304,wherein the polymeric material comprises one or more polyolefins.

Aspect 306. The foam midsole of any one of Aspect 290-Aspect 305,wherein the polymeric material includes an ethylene-vinyl acetate (EVA)copolymer, or a styrene polymer, or both.

Aspect 307. The foam midsole of any one of Aspect 290-Aspect 306,wherein the foam midsole has a density of about 0.10 grams per cubiccentimeter to about 0.35 grams per cubic centimeter.

Aspect 308. The foam midsole of any one of Aspect 290-Aspect 307,wherein the foam midsole has an efficiency of at least 70 percent, or anenergy return of at least 20 millijoules, or both, when determined inaccordance with Efficiency Test Method.

Aspect 309. An article of footwear comprising the foam midsole of anyone of Aspect 290-Aspect 308.

From the foregoing, it will be seen that aspects herein are well adaptedto attain all the ends and objects hereinabove set forth together withother advantages which are obvious and which are inherent to thestructure.

While specific elements and steps are discussed in connection to oneanother, it is understood that any element and/or steps provided hereinis contemplated as being combinable with any other elements and/or stepsregardless of explicit provision of the same while still being withinthe scope provided herein.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

Since many possible aspects may be made without departing from the scopethereof, it is to be understood that all matter herein set forth orshown in the accompanying drawings and detailed description is to beinterpreted as illustrative and not in a limiting sense.

It is also to be understood that the terminology used herein is for thepurpose of describing particular aspects only, and is not intended to belimiting. The skilled artisan will recognize many variants andadaptations of the aspects described herein. These variants andadaptations are intended to be included in the teachings of thisdisclosure and to be encompassed by the claims herein.

Now having described the aspects of the present disclosure, in general,the following Examples describe some additional aspects of the presentdisclosure. While aspects of the present disclosure are described inconnection with the following examples and the corresponding text andfigures, there is no intent to limit aspects of the present disclosureto this description. On the contrary, the intent is to cover allalternatives, modifications, and equivalents included within the spiritand scope of the present disclosure.

EXAMPLES

Now having described the aspects of the present disclosure, in general,the following Examples describe some additional aspects of the presentdisclosure. While aspects of the present disclosure are described inconnection with the following examples and the corresponding text andfigures, there is no intent to limit aspects of the present disclosureto this description. On the contrary, the intent is to cover allalternatives, modifications, and equivalents included within the spiritand scope of the present disclosure.

Example 1. Compression Testing of an Exemplary Midsole

A Nike Pegasus 35 running shoe having a midsole comprising Nike Reactfoam material was prepared. FIG. 9A shows a representative side view ofthe midsole used to obtain the data in this example. The same mold wasused to mold the control midsole and the exemplary midsole. A controlmidsole was prepared from a foam preform which was compression molded byconventional compression molding techniques such that there wassubstantially no gap between the preform and mold wall and no internalgaps within the preform prior to compression molding. The exemplarymidsole was prepared from a foam preform having a modified shape suchthat it had the same total volume as the control preform but wasnarrower than the control preform. The exemplary preform did not includeany internal gaps. When the exemplary preform was placed in the moldcavity, a uniform mold gap was present along the midsole perimeter onboth the outer and inner lateral edges. The shape of the exemplarypreform was such that the mold gap was essentially ⅜ at any point alongthe length of the midsole perimeter and essentially no mold gap at theheel and toe ends of the preform when the exemplary preform was arrangedin the mold cavity. The mold gap was calculated for any given point asfollows:

${MG} = \frac{\left( {{Mi{dsole}{mold}{width}} - {Mi{dsole}{preform}{width}}} \right)}{\left( {{Midsole}{mold}{width}} \right)}$

The preforms were arranged in the mold cavity, the mold was closed withcompression, and compression molding was carried out on the preforms inthe closed mold by heating the closed mold with a platen placed incontact with the top of the mold. To monitor the temperature of thepreform during the molding, a thermocouple was inserted into the centerof the preform at the thickest part. Once the internal temperaturereached 160 degrees C., the foam preforms were at that temperature foran additional 4 minutes. Following the molding, the closed mold wascooled before the mold was opened and the compression molded midsoleremoved. The compression mold machine settings were as follows: (a)temperature set to 170 degrees C.; and (b) pressure (for both hot andcold sides) set to 2000 psi. Compression molding times were as follows:(a) platen (at 160 degrees C. platen temperature) was 1410 seconds; (b)internal part (at 160 degrees C. internal temperature) was 2070 seconds;and (c) 35 degrees C. (cool down temperature, required minimum), first1236 seconds/second 1157 seconds. Temperatures: (a) internal part at thecompletion of hot press cycle, first 169 degrees C./second 168.2 degreesC.; (b) machine reading at the completion of the press cycle, 174.5degrees C. (overshoot); and (c) machine reading at the completion ofcold press cycle, 7.9 degrees C.

For efficiency testing, the control and exemplary compression midsoleswere compressed in the heel and forefoot using a last pressure matchedto a performance runner's running stride. Compression testing wasperformed on an ElectroPuls E10000 using a last-shaped tupp sized tocorrespond to the size of the midsole being tested. Experiments were runin force control mode up to a maximum load of 600 newtons using awaveform which mirrors performance runner's footstrike force profile.The waveform employed a half period of sine wave to apply an impulse.After the impulse was complete, the midsole was left unloaded for theremainder of the cycle. The load-rest cycle was repeated for the desirednumber of cycles. Waveform details: pulse amplitude=600 N; pulsewidth=0.2 seconds; pulse shape=half period of sine wave; and rest=0.8seconds, repeat. FIG. 9B shows a photographic image showing the testingsetup used.

Briefly, 100 compressive cycles were performed at ˜1.1 hertz.Compressive stiffness, efficiency, and energy return are measured fromthese tests. Compressive stiffness for each cycle corresponds to thepeak load normalized by the deflection at that max load. For foamarticles such as midsoles (i.e., any non-plaque geometry) stiffness isreported in N/mm. Efficiency is the integral of the unloading loaddeflection curve divided by the integral of loading load deflectioncurve. Energy return is the integral of the unloading load deflectioncurve. The values reported for an individual midsole are the average ofthe 60^(th), 70^(th), 80^(th) and 90^(th) cycles. An example loadingseries of curves for one midsole are shown below. The relevant metricsare indicated on the graph where “stiff”=compressive stiffness [N/mm]“energy out”=energy return [mJ], and “eff”=efficiency. The data shown inTable 1 are the average of at least two midsoles for each condition.Representative cyclic loading for the midsole is shown in FIG. 7 (heeltesting).

TABLE 1 Heel Forefoot Control* MG** Control MG** Stiffness [N/mm] 61 48105 87 Energy Return [mJ] 1420 1960 841 1100 Efficiency 0.735 0.83 0.730.80 *Control sample is a midsole prepared by conventional compressionmolding methods with substantially no gap between the preform and moldwall. **MG refers to mold gap, which in the test sample was 3/8; andthese data refer to the exemplary midsole of Example 1 in which themidsole was prepared with anisotropic closed cell foam structure.

Example 2. Compression Testing of an Exemplary Plaque

Compression molded foam plaques were prepared using the disclosedcompression molding methods using the same mold to form a plaque foampreform comprising Nike React foam materials, e.g., foam materials asused in the midsole of a Nike Epic React Flyknit shoe. Six plaquepreforms (R2-R7) were prepared having the dimensions described in Table2 below. In particular, as listed in Table 2, each preform plaque haddimensions such that there was the indicated mold gap between each ofthe outside long edges of the plaque and the mold. None of the preformplaques included internal gaps, and all of the preforms hadsubstantially the same total volume. Accordingly, specimen R2 having nogap between the plaque preform and the mold represented a control plaquesample for conventional compression molding techniques. Briefly,compression molding conditions for the plaques were as follows: (a)platen set temperature (hot side): 170 degrees Celsius; (b) plate settemperature (cold side): 8 degrees Celsius; and (c) pressure: 2000 psi(on each of the hot and cold sides). Plaques were loaded into the mold,the mold was closed, and the platens were heated to their set point.After the platens reached their setpoint, the closed mold with theplaque was left in the hot press for 4 minutes. The temperature of thecenter of the foam plaque when the platens reached their set point was160 degrees Celsius. At the end of the 4 minutes, the center temperatureof the foams was 172 degrees Celsius. These temperatures were read by athermocouple that was inserted inside of the foam plaque. At the end ofthe 4 minutes, the closed mold was moved to the cold press and cooleduntil the foam temperature was less than 10° C. This typically tookbetween 7-9 minutes. After cooling, the closed mold was opened and thecompression molded plaque was removed.

TABLE 2 Absolute Dimen- Preform Preform Preform Gap on sionless Speci-Width Height Length Each side Gap men [millimeter] [millimeter][millimeter] [millimeter] [MG] R2 80 16 180 0 0 R3 70 18.3 5 0.125 R4 6021.3 10 0.25 R5 50 25.6 15 0.375 R6 40 32 20 0.5 R7 30 42.7 25 0.625

All plaques were tested following compression molding described aboveusing an ElectroPuls E10000 equipped with a cylindrical tupp where thecontacting diameter was 44.86 millimeter. A total of 500 sinusoidalcompression cycles were performed with a frequency of 2 Hertz and wereforce controlled to 300 N. Compressive stiffness, energy return, andefficiency were measured from these tests. Compressive stiffness foreach cycle corresponds to the peak stress normalized by the strain atmax load where stress and strain are defined as force/area anddeflection/thickness, respectively. Efficiency was the integral of theunloading load deflection curve divided by the integral of the loadingload deflection curve. Energy return was the integral of the unloadingload deflection curve. The metrics reported for an individual plaque arethe average of the 100^(th), 200^(th), 300^(th), and 400^(th) cycles. Anexample loading series of curves for one midsole are shown below. Therelevant data are indicated on the graph where “stiff”=compressivestiffness [kilopascals] and “eff”=efficiency, and “energy out”=energyreturn. Data are shown below for individual plaques.

TABLE 3 Volume Fraction Energy Above Stiffness Return Specimen Fill LineEfficiency [kilopascals] [mJ] R2 0.375 0.80 753 18.8 R3 0.453 0.82 69720.5 R4 0.531 0.84 660 21.5 R5 0.609 0.86 565 26.4 R6 0.688 0.90 54427.1 R7 0.766 0.89 382 29.3

Example 3. Imaging of Cell Structure in Exemplary Foam Materials

Plaque samples were prepared as described above using plaque preformscomprising various ethylene vinyl-acetate foam materials as follows: (a)Foam 1 is a compression molded plaque prepared using a plaque foampreform comprising an ethylene-vinyl acetate copolymer (EVA) foammaterial utilized in the midsole of Nike Epic Lunar Control Models 3 and4 marketed in 2015 and 2016; (b) Foam 2 is compression molded plaqueprepared using a plaque foam preform comprising an EVA foam materialutilized in the midsole of Nike Lunartempo Lunartempo 2 shoe modelsmarketed in 2016 and 2017; (c) Foam 3 is compression molded plaqueprepared using a plaque foam preform comprising an EVA foam materialutilized in footwear midsoles; and (d) Foam 4 is compression moldedplaque prepared using a plaque foam preform comprising Nike React foammaterial as described above. The samples were compression molded asdescribed above. The control sample was molded with no gap betweenpreform and the mold, having the dimensions described above for specimenR2 (MG is essentially 0). A representative sample of an exemplary foammaterial was compression molded with the dimensions and gap between thepreform and molded as described above for specimen R5 (MG=0.375).

Exemplary optical micrographs of the samples described were prepared andanalyzed as follows: Foam 1 (FIG. 10A); Foam 2 (FIG. 10B); Foam 3 (FIG.10C); and Foam 4 (FIG. 10D). Cell aspect ratio was then measured viamicrographic analysis of optical micrographs shown in FIGS. 10A-10D.High contrast optical micrographs were acquired of areas ofrepresentative foam structure. A grid of 48 regularly spaced points wasplaced on each micrograph corresponding to 0.625 square millimeters perpoint. The foam cell contained by each point was fit with an ellipse. Ifa point did not fall within a cell, the cell nearest the point was fit.From the fitted ellipse, the major and minor axes were identified. Theaspect ratio of each cell was approximated by the ratio of the length ofthe major axis relative to the minor axis. The aspect ratio correspondsto the average aspect ratio of all the fitted ellipses for a givensample, and data are shown in Tables 4-7 below for samples Foam 1, Foam2, Foam 3, and Foam 4, respectively.

TABLE 4 Foam 1. Property Control MG* %Δ Stiffness [kPa] 450 350 −22  Efficiency [%] 0.86 0.90  +4.7 Energy Return [mJ] 32 38 +19   CellAspect Ratio 1.27 2.07 *MG is mold gap, which was 3/8 in the foregoingtesting.

TABLE 5 Foam 2. Property Control MG* %Δ Stiffness [kPa] 533 377 −29Efficiency [%] 0.76 0.85 +12 Energy Return [mJ] 26 31 +22 Cell AspectRatio 1.29 2.10 *MG is mold gap, which was 3/8 in the foregoing testing.

TABLE 6 Foam 3. Property Control MG* %Δ Stiffness [kPa] 1070 560 −47  Efficiency [%] 0.78 0.82  +5.1 Energy Return [mJ] 14 25 +78   CellAspect Ratio 1.39 2.43 *MG is mold gap, which was 3/8 in the foregoingtesting.

TABLE 7 Foam 4. Property Control MG* %Δ Stiffness [kPa] 753 565 −25  Efficiency [%] 0.80 0.86  +7.5 Energy Return [mJ] 23 28 +22   CellAspect Ratio 1.33 2.73 *MG is mold gap, which was 3/8 in the foregoingtesting.

In the foregoing tables, mold gap (MG) is, because of the shape of theplaque samples and plaque mold, calculated as follows:

${MG} = {\frac{\left( {{{Plaque}{mold}{width}} - {{preform}{width}}} \right)}{\left( {{Plaque}{mold}{width}} \right)}.}$

In all four tests described above (Tables 4-7 and FIGS. 10A-10D), themolding method disclosed herein was effective in: (a) decreasing thestiffness of each foam by at least 20 percent; (b) increasing theefficiency of each foam by over 4.5 percent; and (c) increasing theenergy return of each foam by at least 15 percent, as compared to thecontrol foams comprising the same polymeric material and substantiallysimilar densities molded using a conventional compression moldingprocess. The micrographs of the corresponding foam structures showsignificant alterations to the cell shapes in the foam structures of theexemplary foams. In all four test samples prepared using the disclosedmolding methods, the average cell aspect ratios were found to be greaterthan two, with increases of at least 0.8 over the conventionallycompression molded control foams, which had substantially isotropiccells in their foam structures.

It should be emphasized that the above-described aspects of the presentdisclosure are merely possible examples of implementations, and are setforth only for a clear understanding of the principles of thedisclosure. Many variations and modifications may be made to theabove-described aspects of the disclosure without departingsubstantially from the spirit and principles of the disclosure. All suchmodifications and variations are intended to be included herein withinthe scope of this disclosure.

What is claimed:
 1. A compression molded foam article, wherein thecompression molded foam article made by a process comprising: arranginga preform in a compression mold; wherein the preform comprises apolymeric foam material having a closed cell foam structure; wherein thepreform is associated with a preform x-axis, y-axis, and z-axis suchthat each axis is perpendicular to the other two; wherein the preformhas a preform longitudinal dimension parallel to the preform y-axis of apreform x-y plane; wherein the preform z-axis is parallel to a directionof compression applied to the compression mold; wherein the preform hasa preform height that is a dimension parallel to the preform z-axis;wherein the preform has an initial preform height equal to the preformheight prior to compression molding; wherein the compression moldcomprises a mold cavity; and wherein the mold cavity is associated witha mold cavity x-axis, y-axis, and z-axis such that each axis isperpendicular to the other two; wherein the mold cavity has a moldcavity longitudinal dimension parallel to the mold cavity y-axis of amold cavity x-y plane; wherein the mold cavity z-axis is parallel to thedirection of compression applied to the compression mold; wherein themold cavity has a mold cavity height that is a dimension parallel to thepreform z-axis when the mold is closed; wherein the arranging comprisesaligning the preform x-axis, y-axis, and z-axis with the mold cavityx-axis, y-axis, and z-axis; and wherein an initial preform height isfrom 1.1- to 5-fold greater than the mold cavity height; closing thecompression mold and compressing the preform into a closed mold cavity;applying heat, pressure, or a combination of both to the closed moldcavity for a duration of time to: (a) alter at least one preformdimension along the preform x-axis, y-axis, and z-axis; and (b) alterthe closed cell foam structure to a closed cell foam structure having agreater proportion of anisotropic cell shapes; forming the compressionmolded foam article; opening the compression mold after the least onepreform dimension in the preform x-axis, y-axis, and z-axis and theclosed cell foam structure are altered; removing the compression moldedfoam article from the compression mold; and wherein the compressionmolded foam article retains dimensions of the closed mold cavity withinplus or minus 50 percent; and wherein the compression molded foamarticle has the closed cell foam structure having a greater proportionof closed cells with the anisotropic cell shapes as compared to thepreform, or having substantially the same proportion of closed cellswith the anisotropic cell shapes as compared to the preform, where anaverage aspect ratio of the proportion of the closed cells with theanisotropic cell shapes is greater as compared to the preform, or boththe proportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the closed cell foam structure of thecompression molded foam article as compared to the closed cell foamstructure of the preform; characterized in that, either: (A) the preformhas a preform area comprising an area of the preform x-y plane and thepreform has an initial preform area that is the preform area prior tocompression molding; and the mold cavity has a mold cavity areacorresponding to an area of a mold cavity bottom and the mold cavitybottom is a mold cavity x-y plane opposite a mold cavity opening;wherein the initial preform area is less than about 75 percent of themold cavity area, or (B) the preform has a plurality of initial preformwidths; wherein each initial preform width of the plurality of initialpreform widths is designated as IPW_(i), wherein i is an integer havinga value of 1 to 100; and each IPW_(i) has a dimension parallel to thepreform x-axis of the preform x-y plane at a position, Y_(i), along thepreform longitudinal dimension prior to compression molding;  the moldcavity has a plurality of mold cavity widths; wherein each mold cavitywidth of the plurality of mold cavity widths is designated as CW_(j),wherein j is an integer having a value of 1 to 100; wherein each CW_(j)has a dimension parallel to the mold cavity x-axis of the mold cavityx-y plane of the preform at a position, P_(j), along the mold cavitylongitudinal dimension; wherein each P_(j) is associated with acorresponding position of the preform longitudinal dimension when thepreform y-axis and the mold cavity y-axis are aligned; and the preformand the mold cavity are associated with a plurality of mold gaps;wherein each mold gap of the plurality of mold gaps is designated asMG_(k), wherein k is an integer having a value of 1 to 100; wherein eachMG_(k) is obtained from the following equation:${MG_{k}} = \frac{{CW}_{j} - {IPW}_{i}}{{CW}_{j}}$ and wherein each moldgap is independently from about 0.200 to about 0.7, or (C) the preformhas a preform volume, wherein the preform has an initial preform volumethat is the preform volume prior to compression molding; and the moldcavity has a mold cavity volume associated with the mold when it isclosed; wherein less than about 80 percent of the mold cavity volume isoccupied by the preform; and at least 50 percent of the initial preformvolume is positioned outside the mold cavity.
 2. The compression moldedfoam article of claim 1, wherein a region of the compression molded foamarticle includes the greater proportion of closed cells with theanisotropic cell shapes, or includes the closed cells with the greateraverage aspect ratio, or both, and the region occupies at least 1 cubiccentimeter of a total volume of the compression molded foam article, andwherein the region does not include an external skin of the compressionmolded foam article.
 3. The compression molded foam article of claim 1,further comprising compressing the preform until a compression ratio of1.2 to 4.0 is achieved; wherein the compression ratio is a ratio ofinitial preform height to mold cavity depth; wherein the initial preformheight is an average height of the preform determined along an axisoriented parallel to the direction in which the compression is appliedduring compression molding; wherein the initial preform height isdetermined prior to compression molding; and wherein the mold cavitydepth is an average depth of the cavity determined along an axisoriented parallel to the direction in which the compression is appliedduring compression molding.
 4. The compression molded foam article ofclaim 1, wherein the compressing the preform into the closed mold cavitycomprises compressing the preform until a final preform height and afinal preform volume are reached; wherein the final preform height isthe preform height when it is equal to the mold cavity height; andwherein the final preform volume is the preform volume when it is equalto the mold cavity volume.
 5. The compression molded foam article ofclaim 1, wherein the initial preform height is from 1.1- to 4-foldgreater than the mold cavity height.
 6. The compression molded foamarticle of claim 1, wherein the compression molded foam article has ananisotropic cell shape having an average aspect ratio that is an averageratio of the y-axis to the z-axis; wherein a major axis is parallel tothe y-axis; wherein a minor axis is parallel to the x-axis; and whereinthe average aspect ratio is from 1.5 to
 15. 7. The compression moldedfoam article of claim 1, wherein the compression molded foam articleexhibits an efficiency as determined along the z axis that is from 1.0percent to 25 percent greater than a reference foam article whendetermined in accordance with an Efficiency Test Method; wherein thereference foam article is a reference preform foam article prior tocompression molding from which the compression molded foam article isformed; wherein the reference preform foam article comprises essentiallythe same polymeric material as the compression molded foam article; andwherein the reference preform foam article has a substantially isotropiccell shape.
 8. The compression molded foam article of claim 6, whereinthe foam article exhibits an efficiency that from 1.0 percent to 25percent greater than a reference foam article when determined inaccordance with Efficiency Test Method; wherein the reference foamarticle is a reference compression molded foam article comprisingessentially the same polymeric material and having substantially thesame density as the compression molded foam article; and wherein thereference compression molded foam article has a substantially isotropiccell shape.
 9. The compression molded foam article of claim 1, wherein40 percent to 100 percent of the compression molded foam articlecomprises the anisotropic cell shape.
 10. A method for making acompression molded foam article, the method comprising: arranging apreform in a compression mold; wherein the preform comprises a polymericfoam material having a closed cell foam structure; wherein the preformis associated with a preform x-axis, y-axis, and z-axis such that eachaxis is perpendicular to the other two; wherein the preform has apreform longitudinal dimension parallel to the preform y-axis of apreform x-y plane; wherein the preform z-axis is parallel to thedirection of compression applied to the compression mold; wherein thepreform has a preform height that is a dimension parallel to the preformz-axis; wherein the preform has an initial preform height equal to thepreform height prior to compression molding; wherein the compressionmold comprises a mold cavity; and wherein the mold cavity is associatedwith a mold cavity x-axis, y-axis, and z-axis such that each axis isperpendicular to the other two; wherein the mold cavity has a moldcavity longitudinal dimension parallel to the mold cavity y-axis of amold cavity x-y plane; wherein the mold cavity z-axis is parallel to adirection of compression applied to the compression mold; wherein themold cavity has a mold cavity height that is a dimension parallel to thepreform z-axis when the mold is closed; wherein the arranging comprisesaligning the preform x-axis, y-axis, and z-axis with the mold cavityx-axis, y-axis, and z-axis; and wherein the initial preform height isfrom 1.1- to 5-fold greater than the mold cavity height; closing thecompression mold and compressing the preform into a closed mold cavity;applying heat, pressure, or a combination of both to the closed moldcavity for a duration of time to: (a) alter at least one preformdimension along the preform x-axis, y-axis, and z-axis; and (b) alterthe closed cell foam structure to a closed cell foam structure having agreater proportion of anisotropic cell shapes; forming the compressionmolded foam article; opening the compression mold after the at least onepreform dimension in the preform x-axis, y-axis, and z-axis and theclosed cell foam structure are altered; removing the compression moldedfoam article from the compression mold; and wherein the compressionmolded foam article retains dimensions of the closed mold cavity withinplus or minus 50 percent; and wherein the compression molded foamarticle has the closed cell foam structure having a greater proportionof closed cells with the anisotropic cell shapes as compared to thepreform, or having substantially the same proportion of closed cellswith the anisotropic cell shapes as compared to the preform, where anaverage aspect ratio of the proportion of the closed cells with theanisotropic cell shapes is greater as compared to the preform, or boththe proportion and the aspect ratio of closed cells with the anisotropiccell shapes are greater in the closed cell foam structure of thecompression molded foam article as compared to the closed cell foamstructure of the preform; characterized in that, either: (A) the preformhas a preform area comprising an area of the preform x-y plane and thepreform has an initial preform area that is the preform area prior tocompression molding; and the mold cavity has a mold cavity areacorresponding to an area of a mold cavity bottom and the mold cavitybottom is a mold cavity x-y plane opposite a mold cavity opening;wherein the initial preform area is less than about 75 percent of themold cavity area, or (B) the preform has a plurality of initial preformwidths; wherein each initial preform width of the plurality of initialpreform widths is designated as IPW_(i), wherein i is an integer havinga value of 1 to 100; and each IPW_(i) has a dimension parallel to thepreform x-axis of the preform x-y plane at a position, Y_(i), along thepreform longitudinal dimension prior to compression molding;  the moldcavity has a plurality of mold cavity widths; wherein each mold cavitywidth of the plurality of mold cavity widths is designated as CW_(j),wherein j is an integer having a value of 1 to 100; wherein each CW_(j)has a dimension parallel to the mold cavity x-axis of the mold cavityx-y plane of the preform at a position, P_(j), along the mold cavitylongitudinal dimension; wherein each P_(i) is associated with acorresponding position of the preform longitudinal dimension when thepreform y-axis and the mold cavity y-axis are aligned;  and the preformand the mold cavity are associated with a plurality of mold gaps;wherein each mold gap of the plurality of mold gaps is designated asMG_(k), wherein k is an integer having a value of 1 to 100; wherein eachMG_(k) is obtained from the following equation:${MG_{k}} = \frac{{CW}_{j} - {IPW}_{i}}{{CW}_{j}}$ and wherein each moldgap is independently from about 0.200 to about 0.7, or (C) the preformhas a preform volume, wherein the preform has an initial preform volumethat is the preform volume prior to compression molding; and the moldcavity has a mold cavity volume associated with the mold when it isclosed; wherein less than about 80 percent of the mold cavity volume isoccupied by the preform; and at least 50 percent of the initial preformvolume is positioned outside the mold cavity.
 11. The method of claim 1,further comprising compressing the preform until a compression ratio of1.2 to 4.0 is achieved; wherein the compression ratio is a ratio ofinitial preform height to mold cavity depth; wherein the initial preformheight is an average height of the preform determined along an axisoriented parallel to the direction in which the compression is appliedduring compression molding; wherein the initial preform height isdetermined prior to compression molding; and wherein the average moldcavity depth is an average depth of the cavity determined along an axisoriented parallel to the direction in which the compression is appliedduring compression molding.
 12. The method of claim 1, wherein thecompressing the preform into the closed mold cavity comprisescompressing the preform until a final preform height and a final preformvolume are reached; wherein the final preform height is the preformheight when it is equal to the mold cavity height; and wherein the finalpreform volume is the preform volume when it is equal to the mold cavityvolume.
 13. A compression molded foam article which is a cushioningelement that is a midsole or midsole component for an article offootwear comprising: an elastomeric material having a closed cell foamstructure comprising a plurality of cells having an anisotropic cellshape; wherein the foam cushioning element comprises a first axis (z), asecond axis (y) and a third axis (x); wherein the first axis (z) isperpendicular to the second axis (y) and the third axis (x); wherein thesecond axis (y) and the third axis (x) are each perpendicular to eachother; wherein the second axis (y) and the third axis (x) define a plane(x-y) parallel to a major surface of the foam article; wherein theplurality of cells are aligned in an orientation along the second axis(y) within a range of a solid angle of plus or minus 20 degrees; andwherein a physical property determined along the first axis (z) isdifferent from the physical property determined along the second axis(y), the third axis (x), or both the second (y) and third axis (x). 14.The foam cushioning element of claim 13, wherein the plurality of cellshave an average aspect ratio that is an average ratio of the second axis(y) to the first axis (z); wherein a major axis is parallel to thesecond axis (y); wherein a minor axis is parallel to the first axis (z);and wherein the average aspect ratio is from 1.5 to
 15. 15. The foamcushioning element of claim 13, wherein the plurality of cells arealigned in an orientation along the second axis (y) within a range of asolid angle of plus or minus 15 degrees.
 16. The foam cushioning elementof claim 13, wherein the plurality of cells having an anisotropic cellshape are dispersed throughout the foam article.
 17. The foam cushioningelement of claim 16, wherein the plurality of cells having theanisotropic cell shape are present in a region of the foam article thatdoes not include an external skin of the compression molded foamarticle, and the region occupies at least 1 cubic centimeter of a totalvolume of the foam article.
 18. The foam cushioning element of claim 13,wherein: the foam cushioning element has a foam cushioning elementvolume; and wherein the plurality of cells having anisotropic cellshapes comprising a percent of the foam cushioning element volume thatis from 10 percent to 100 percent; or wherein the foam cushioningelement has a foam cushioning element weight; and wherein the pluralityof cells having an anisotropic cell shape comprising a percent of thefoam article weight that is from 10 percent to 100 percent.
 19. The foamcushioning element of claim 13, wherein the efficiency in the first axisof the foam cushioning element, when determined in accordance with anEfficiency Test Method, is from about 60 percent to about 99 percent.20. The foam cushioning element of claim 19, wherein the efficiency ofthe foam cushioning element determined along the first axis (z) is atleast 5 percent greater than the efficiency of the foam cushioningelement determined along the second axis (y), the third axis (x), orboth the second (y) and third axes (x) of the foam cushioning element.